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Advanced CNC Knife Cutting

High-speed digital cutting for paper-based boards, foams, packaging, and displays.


  Start a CNC Knife Cutting Project

High-speed digital cutting for paper-based boards, foams, packaging, and displays.

At Barbados PolySolutions, our CNC knife cutting services are powered by 865FabLab and built for accuracy, clean edges, and material integrity. We deliver precise cuts across rigid and flexible sheet materials with no charring, melting, or edge deformation. Whether working with structural cardboard such as Re-board®, Swedboard®, or foam-based materials, our systems produce production-ready parts with speed and consistency.

What We Offer

Our digital knife table supports:

  • Straight cuts, contour cuts, and complex shape profiles
  • V-grooving and bevel cuts for foldable structures and angled edges
  • Creasing and scoring for packaging, displays, and folding parts
  • Camera registration system for precise alignment with printed artwork
  • Kiss-cutting and perforation for peel-away layers or templates
  • Rapid prototyping and short-run production
  • Zero-tooling workflows — perfect for fast iteration and low setup costs

Key System Capabilities

  • Cutting Thickness: Up to 1.5 inches (material dependent)
  • Tool Heads: Oscillating knife, drag knife, V-cut, creasing wheel, optional spindle
  • Camera Registration: Accurate cut-to-print alignment
  • Vacuum Hold-Down: Zoned, high-flow vacuum system
  • Repeatability: ±0.1 mm

Materials We Commonly Cut

  • Re-board®, Swedboard®, Falconboard®, Xanita

  • Corrugated cardboard and paperboard

  • Foam board, PVC-free foam sheets, Gatorfoam®

  • Rubber foam sheets and gasket materials

  • Vinyl sheets and magnetic media

  • Adhesive-backed laminates

  • Textiles, felt, and craft paper

Why Use Knife Cutting Over Laser or CNC?

  • No heat distortion — perfect for foam, adhesives, and paper-based materials

  • No tool marks or burns — ideal for client-facing display work

  • Lower cost for low-volume or prototype runs (no tooling required)

  • Faster turnaround for large-format printed projects that require precise contour cutting

Ideal Applications

  • Structural displays and retail merchandising

  • Foldable, flat-pack furniture or fixtures

  • Trade show booths and pop-up structures

  • Branded signage with depth and dimension

  • Custom packaging, inserts, and presentation kits

  • Templates, gaskets, and precision foam shapes

  • Sustainable construction and demo environments

CNC Knife Cutting FAQ's

Yes — our system uses a camera registration system to align cuts perfectly with pre-printed graphics or logos.

We can cut up to around ½" (12 mm) depending on the material, with excellent accuracy and edge control.

Yes — we offer V-grooves, score lines, and foldable edge treatments ideal for 3D structures or cardboard furniture.

Absolutely — perfect for label sheets, peel-back designs, and packaging templates.

We offer both. Orders can be picked up at our Powell, TN facility or shipped anywhere in the USA.