Laminating Services & Material Bonding
Engineered multi-layer lamination and material bonding that combines foams, films, foils, fabrics, and gasket materials into functional stack-ups, across 687+ engineered materials and 50 chemistries. It runs as two method routes — PSA lamination for pressure-sensitive constructions and custom coating for applied adhesive and functional coatings — alongside multi-layer and dissimilar-material bonding. Output ships as laminated rolls and sheets or feeds straight into die cutting. Converted to your spec in Winsted, Connecticut.
Built for: routing each construction to the right method — multi-layer stack-ups, PSA-backed parts, thermal and EMI laminates, custom-coated materials, and dissimilar-material bonding — supplied as rolls, sheets, or die-cut parts.
Laminating & material bonding at H-O Products combines foams, films, foils, fabrics, and gasket materials into engineered multi-layer stack-ups. Multi-layer lamination builds functional constructions such as foam+film, shielding+adhesive, and thermal laminates; PSA lamination applies single- and double-sided pressure-sensitive adhesive with release liners. The remaining zones and duties are mapped in the When-to-spec list on this page. Values are per the TDS on file.
- Multi-layer stack-ups: foam+film, shielding+adhesive, and thermal laminates built layer by layer to your construction
- PSA lamination: single- and double-sided AFTC acrylic foam tapes and PSAs with the release liner your line needs
- Gasket stack-ups: BISCO® sponge and PORON® laminated to a carrier or PSA backing
- Dissimilar-material bonding: different surface energies, textures, and thicknesses bonded into one construction
- Selective pattern adhesive: adhesive applied only where the part needs it, not edge to edge
- Discrete shaped parts: laminate fed straight into die cutting rather than supplied as a roll
Which lamination capability do you need?
Two in-house routes cover most laminating and bonding work. Pick the one that matches your construction — or send the stack-up and engineering will route it.
Lamination route 1
PSA Lamination
Single- and double-sided pressure-sensitive adhesive: transfer films, double-coated tapes, and PSA laminated to foams, films, and gaskets with the release liner your line needs.
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Lamination route 2
Custom Coating & Selective Adhesive
Adhesive applied only where the design needs it: zone, pattern, and selective coating on 687+ materials, with liners configured for peel-and-place assembly.
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Not sure?Send the stack-upLayers, thicknesses, and what the part must survive. Engineering picks the method and comes back with a DFM review and quote.Go to the quote formLaminating and material bonding, run in-house
Laminating combines two or more materials into a single bonded construction. Material bonding joins dissimilar layers, foam to film, foil to fabric, shielding to adhesive, into a functional stack-up. H-O performs both in Winsted, with the adhesive system, surface prep, and bond integrity matched to each construction, and can feed the laminate straight into die cutting in the same workflow.
What makes the operation different is the depth of the material inventory and the material knowledge behind it. The same materials we laminate, from AFTC acrylic foam tapes and PSAs to BISCO® sponge, PORON®, foils, and Kapton®, is stock we already convert, so we know how each chemistry behaves when bonded: which surfaces wet out cleanly, which need a primer or a transfer adhesive, and which need controlled nip pressure and tension to laminate flat without wrinkles or trapped air.
Multi-layer lamination, PSA lamination, dissimilar-material bonding, and lamination fed in-line into die cutting are performed in Winsted, CT. When a part is better served as a die-cut shape than a laminated roll, we run flatbed die cutting instead, or feed the laminate into the die in-line. See the process comparison below.
Roll-to-roll, sheet & in-line lamination
Laminating covers a few distinct methods, each suited to different materials and constructions. We select the method by the materials being bonded and the format the part requires.
Roll-to-roll lamination
Two or more webs are brought together continuously through a laminator nip and wound as a bonded roll. Well suited to films, foils, foams, and PSAs, where it builds a uniform laminate at production volume.
Sheet lamination
Materials are laminated as discrete sheets rather than a continuous web. The method for thicker and rigid stock, gasket materials, and short runs, where sheet handling holds registration on heavier constructions.
PSA lamination
A single- or double-sided pressure-sensitive adhesive and release liner are laminated to a material to make it self-adhesive. Common for foams, foils, and shielding that ship as PSA-backed stock or die-cut parts.
In-line laminate-to-die
Layers are laminated and fed directly into die cutting in one pass, so the converted part is cut from the finished laminate without a separate lamination handoff.
The method and adhesive are calibrated per construction. A 0.002″ Kapton® film laminates cleanest on a roll-to-roll line with controlled nip; a 0.125″ BISCO® sponge stack-up or a heavy gasket laminate often runs better as sheet lamination. Tell us the layers, thicknesses, and adhesive, and we will set the method and the nip and tension so the laminate bonds flat.
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1Send spec & materialShare the layer-by-layer construction, the adhesive system, single- or double-sided, the release liner, and the supply format, with each material grade and thickness. A sample part works too.
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2Method & bond reviewEngineering selects the lamination method (roll-to-roll, sheet, or in-line), sets the nip and tension, and confirms the adhesive and liner against your construction and service conditions.
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3First samplesSample laminates typically 3-5 business days for common configurations. Standard production 2 weeks; special orders run custom lead times.
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4ProductionLaminated, bonded, and labeled to spec, or fed in-line into die cutting, with first-article bond checks and lot-code traceability carried through the run.
Send the stack-up and get a lamination review
If you have the layer construction, adhesive, and liner, send the spec or a sample part. Engineering selects the method, sets the nip and tension, and comes back with a quote.
What we laminate, and for whom
Multi-layer laminates, PSA-backed constructions, gasket stack-ups, and laminate-to-die feedstock ship into medical, aerospace, defense, electronics, industrial, energy, and transportation programs.
- Thermal & EMI laminates
- Films, foils, and shielding materials laminated into thermal and EMI constructions, with the adhesive and facing selected to the interface, supplied as rolls or sheets or fed in-line into die cutting. Peel, shear, and tack values are validated to your substrate, surface prep, and service conditions.
- Gasket stack-ups
- BISCO® sponge, PORON®, and rubber gasket materials laminated to a carrier or a single- or double-sided PSA backing, for seals that ship ready to apply. See the engineered sealing and gasketing application overview for how those seals are specified.
- PSA-backed parts
- Foams, foils, and shielding laminated with single- or double-sided PSA and a release liner, then to shape, so the finished part lifts off the liner and applies directly. Laminated acrylic foam tape is the bonding layer behind much of our structural bonding and fastener-replacement work.
- Multi-layer foam+film insulators
- Foam bonded to film and foil into multi-layer insulating and cushioning constructions, with selective pattern adhesive where the part needs a clear zone, blanked from the finished laminate in one coordinated pass with registration held between the layers and the cut.
AFTC 5344 acrylic foam tape laminated to a 0.060″ foam carrier with a differential-release liner across 4 part numbers, bonded at controlled nip and tension for a flat, air-free construction fed in-line into die cutting. Peel, shear, and tack values are validated to your substrate, surface prep, and service conditions. Quality systems are built for medical, aerospace, and defense programs, with lot traceability typically retrievable in under 2 hours.
Laminating & material bonding questions
Common questions from engineers speccing laminated and bonded constructions.
What is the difference between multi-layer lamination, PSA lamination, and dissimilar-material bonding?
Multi-layer lamination builds two or more functional layers into one construction, such as foam+film or shielding+adhesive. PSA lamination applies single- or double-sided pressure-sensitive adhesive and a release liner to make a material self-adhesive. Dissimilar-material bonding joins materials with different surface energies, textures, and thicknesses, matching an adhesive or surface prep to each interface. We pick the approach by the materials, the construction, and the service conditions.
What laminate thicknesses and tolerances can you hold?
We laminate to the built-up thickness on your spec. Each layer adds to the finished thickness, so the tolerance depends on the construction. Give us the layer-by-layer stack-up and the thickness tolerance the application needs, and we will confirm what the materials and method can hold. Specify a tight tolerance only where it matters to keep converting cost down.
What lamination formats can you supply?
Roll-to-roll laminates wound as bonded rolls, sheet laminates for thicker or rigid constructions, and PSA-backed stock with a release liner. We can also feed the finished laminate in-line into die cutting instead of supplying a separate roll. We laminate to your construction, release liner, and supply format.
Can you apply single- and double-sided PSA and select the release liner?
Yes. We laminate single- and double-sided pressure-sensitive adhesive to your material and select the release liner your line needs, paper or film, single- or differential-release. Tell us the adhesive system, the sides, and how the part dispenses and applies, and we laminate and label to that spec.
What materials can H-O Products laminate and bond?
Materials from the same 687+ SKU inventory we convert: AFTC acrylic foam tapes (126+), acrylic, rubber, and silicone PSAs and transfer tapes (28+), films and foils including Kapton® and conductive foil, BISCO® silicone sponge (100+), PORON® and cellular urethanes (80+), and rubber and cork-rubber gasket materials and fabrics. Tell us the layers and thicknesses in your construction.
How do you bond dissimilar materials that do not normally stick?
By matching the adhesive and surface prep to each interface. A low-surface-energy film, a rough foam, and a smooth foil each bond differently, so we may use a different adhesive on each face, a transfer adhesive between them, or a primer. Peel, shear, and tack values are validated to your substrate, surface prep, and service conditions, not quoted as one universal number.
Can you laminate my own materials?
Yes. We laminate and bond customer-supplied materials as well as stock from our own inventory. Send each material grade, thickness, and dimensions, along with the construction, adhesive, and release liner, and we will confirm the method and set up the run.
Can laminating be combined with die cutting?
Yes. We feed the finished laminate directly into die cutting in one coordinated workflow, which removes a separate lamination handoff and holds registration between the layers and the cut. That is common when a PSA-backed gasket or a multi-layer insulator is blanked from a completed stack-up.
Related converting capabilities
Laminating sits inside a connected set of in-house converting capabilities. These pages cover the adjacent processes that often share the same construction.
Capability overview
Converting & Fabrication
The parent hub: how die cutting, waterjet, laser, rotary, laminating, and profiling fit together, and which process suits which part, material, and volume.
Read the overview
Related capability
Rotary Die Cutting
High-volume roll-fed converting of acrylic foam tapes and thin foams.
Read the page
Related capability
Precision Die Cutting
Flatbed die cutting for discrete gaskets.
Read the page
Talk to an engineer
Contact H-O Products
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Last updated · Reviewed by H-O Products engineering (ISO 9001:2015 certified converter, Winsted, CT).
Standards & references
The standards, test methods, and vendor technical data sheets cited on this page. Verify current editions against the publishing body before final spec.
ISO 9001:2015
ISO 9001:2015, Quality management systems — Requirements. International Organization for Standardization. H-O Products is an ISO 9001:2015 certified organization; Clauses 7.5 (documented information) and 8.5.2 (identification and traceability) govern the laminate-to-layer-lot linkage and records referenced on this page.
ASTM D3330 / D3330M
ASTM D3330 / D3330M, Standard Test Method for Peel Adhesion of Pressure-Sensitive Tape. ASTM International, West Conshohocken, PA. The peel-adhesion method referenced for PSA-laminated constructions; the specified condition is a 180 degree peel at 300 mm/min, and the peel value itself is the value on the vendor TDS, validated to the application.
ASTM D3652 / D3652M
ASTM D3652 / D3652M, Standard Test Method for Thickness of Pressure-Sensitive Tapes. ASTM International. The thickness-measurement method referenced for laminate layers, since each layer thickness sets the built-up laminate thickness; the thickness value is per the vendor TDS.
ASTM D3654 / D3654M
ASTM D3654 / D3654M, Standard Test Methods for Shear Adhesion of Pressure-Sensitive Tapes. ASTM International. The static-shear method referenced where a PSA-laminated construction must hold under load; the shear time is per the vendor TDS, validated to the application.
ISO 2768
ISO 2768-1, General tolerances — Tolerances for linear and angular dimensions without individual tolerance indications. The general-tolerance reference used when a built-up laminate thickness on the spec does not carry an individual tolerance; medium class m holds 6 mm to 30 mm to plus or minus 0.2 mm.
ASTM D1000
ASTM D1000, Standard Test Methods for Pressure-Sensitive Adhesive-Coated Tapes Used for Electrical and Electronic Applications. ASTM International. Referenced when a laminated construction includes an electrical tape and its electrical and physical properties are confirmed against the vendor TDS.
Source-manufacturer TDS
Material properties, thicknesses, surface energies, adhesive systems, and service-temperature ranges are taken from the source-manufacturer technical data sheets for the construction (for example Rogers BISCO silicone, Rogers PORON, DuPont Kapton, and tape manufacturers). Confirm against the current vendor TDS for your specific construction before final specification.
For an accurate quote, include the following with your drawing or sample:
- Layer construction
- Each material grade
- Thickness
- Adhesive system
- Single- or double-sided
- Release liner
- Supply format
Request a laminating quote
Send your laminate spec, a sample part, or a description of the construction. Engineering selects the method, sets the nip and tension, and comes back with a quote.
Material data & standards. Material properties, temperature ranges, thicknesses, and lamination parameters referenced on this page are taken from the source manufacturers' technical data sheets and the cited industry references. H-O Products converts, laminates, and bonds these materials; we do not independently re-certify them against the standards unless explicitly stated on the quote.
Peel, shear, and tack values are validated to your substrate, surface prep, and service conditions, and achievable bond performance is material- and construction-dependent. Verify against your application and the vendor TDS for your specific construction. Lot-specific documentation is available on request.
Capability scope. Multi-layer lamination, PSA lamination, dissimilar-material bonding, and lamination fed in-line into die cutting are performed in-house in Winsted, CT. Lead times and minimums vary by material, construction, and format; expedited handling can be arranged.