Dear All

Anyone have any ideas on how to kiss-cut 30 micron aluminium foil laminated onto expanded PVC sheet?

Tried: Die cutting, laser (CW and Q-switched), milling, V-cutting, ultrasonic knife.

There should be no electrical connection between the cut.
Milling and V-cutting leave swarf (mixed with the foil adhesive) which leads to short circuits being formed.
Die cutting just deforms the aluminium around the cutter as it is very ductile.
Laser is too slow (Q-switched), too hot (CW).
Knife works but is blunt very quickly.

Desperate to find a solution as we have a show mid November with no product!

Many thanks in advance to all
Karl