A Millimeter-Level Revolution in Precision Cutting: The Art of Precision Control in Poron Mouse Pad Production

In the Poron mouse pad production process, cutting is the crucial link between semi-finished and finished products, the “last mile” that determines the final product form and user experience. As a source factory with 19 years of experience.

We’ve evolved from manual cutting (2006) to semi-automatic punching (2012) and finally to fully automated CNC laser cutting (2022).

We deeply understand the industry truth that “millimeter-level precision determines user experience”—for esports players, a 0.1mm cutting deviation can cause a “stuttering” feeling when moving the mouse.

For office users, irregular edges can scratch wrists; and for bulk orders, a 1% cutting defect rate means thousands of units are scrapped. By 2025, our laser cutting equipment had achieved a stable accuracy of ±0.1mm.

This achievement was the result of over 20 million RMB in equipment investment, 5,000 hours of process debugging data, and 12 independently developed cutting-assist technologies. It also reflects our unwavering commitment to craftsmanship.

1. The Limitations and Upgrades of Traditional Cutting: The Leap from Punching to Laser

In the early days of our factory (2006-2012), we primarily used manual cutting and mechanical punching. Manual cutting relied on worker experience, using a utility knife and a steel ruler.

Accuracy depended entirely on operator proficiency—even the most skilled workers could only maintain an error of ±1mm, and the edge burr rate was as high as 8%.

Our daily production capacity was limited to 500 pieces, which was insufficient to meet the demands of large orders.

In 2010, we received an order for 10,000 office mouse pads from a certain brand. Due to a 7% defective rate during manual cutting, we needed to rework and delayed delivery by 15 days.

Not only did we have to pay a 5% penalty, but we also nearly lost this important customer. This lesson taught us that traditional manual cutting was no longer suitable for industrial production and that we needed to upgrade our equipment.

In 2012, we introduced our first batch of semi-automatic punching machines (model: J21-16), enabling batch cutting using customized molds.

The punching machine significantly improved cutting accuracy compared to manual cutting, achieving an error of ±0.5mm and reducing the burr rate to 3.2%. This increased our daily production capacity to 5,000 pieces, essentially meeting market demand at the time.

However, punch cutting also has natural limitations: first, the mold cost is high. The design and production cost of a single set of molds (material: Cr12MoV) is about 8,000 yuan, and a set of molds can only correspond to one size and shape.

For small-batch customized orders (such as less than 500 pieces), the mold cost per product is as high as 16 yuan, far exceeding the customer’s cost expectations; second, the flexibility is poor. Replacing the mold requires disassembly, installation, and debugging.

The whole process takes 2-3 hours, and it is impossible to respond quickly to multiple varieties of orders; third, the damage to Poron material is relatively large.

The instantaneous impact force of the punch (about 160kN) may cause the foam structure of the Poron material to be destroyed, especially thin materials below 2mm.

The edges are prone to “collapse” after punching (the edge is concave by 0.2-0.3mm). In 2018, with the explosive growth of the esports market.
Demand for Poron mouse pads in large sizes (such as 900x400mm) and with unusual shapes (such as team-specific ones with curved edges) surged, further exacerbating the limitations of punch cutting.
We once attempted to customize a 300x350mm custom mouse pad for an esports team. Because the mold couldn’t achieve the complex curved edges, we ultimately resorted to punching and manual trimming.

This method was not only inefficient (only 300 pieces per day), but also resulted in edge accuracy deviations of ±0.8mm and a customer satisfaction rate of only 70%. This failure reassured us and led to the research and introduction of laser cutting equipment.

After two years of technical research and equipment comparison, we introduced our first batch of fiber laser cutting machines (model: GF-1325) in 2020, and fully upgraded to the fifth-generation equipment (model: GF-1530) in 2022.

Compared with punching machines, laser cutting has obvious advantages: First, it has high precision.

Through CCD visual positioning (accuracy ±0.05mm) and a dynamic focusing system, the cutting error can be controlled to ±0.1mm, which fully meets the edge precision requirements of e-sports mouse pads.

Second, it has good flexibility. No mold is required. Only graphic files need to be imported into the software to achieve cutting of different sizes and shapes, and the production change time is shortened from 2 hours to 15 minutes.

Third, it causes little damage to the material. The non-contact cutting of the laser does not generate mechanical stress. The foam structure integrity rate of Poron material reaches 99%, and there is no edge collapse or burr phenomenon.

Fourth, it has high efficiency. The maximum operating speed of the fifth-generation equipment reaches 120m/min, which is 4 times that of the punching machine.

The daily production capacity of a single device can reach 8,000 pieces. In 2024, we customized a limited-edition mouse pad for a well-known esports team (with a contoured edge and a cutout team logo).

Using laser cutting, we achieved a perfect fit between the pattern edge and the functional area, with an edge accuracy deviation of ≤±0.08mm. The product achieved a 2.3-fold premium over the regular model and sold out within 72 hours, demonstrating the technical advantages of laser cutting.

2. Laser Cutting Equipment Selection and Process Debugging: Data-Driven Precision Control

Selecting laser cutting equipment is a complex technical decision, requiring comprehensive consideration of multiple factors, including Poron material properties, product specifications, and production capacity requirements.

When upgrading to our fifth-generation equipment in 2022, we focused on the following core parameters:

First, laser type and power. Poron is a polyurethane foam, which is heat-sensitive. Therefore, we chose a fiber laser (1064nm) with a shorter wavelength and smaller heat-affected zone, rather than a CO₂ laser (10.6μm).

The heat-affected zone (approximately 0.5mm) of a CO₂ laser can carbonize and harden the edges of Poron, affecting its tactile feel. In contrast, the heat-affected zone of a fiber laser is only 0.1mm, resulting in a smooth edge and maintaining Poron’s inherent softness.

Regarding power, we experimentally determined a range of 80-150W: for Poron materials 2-3mm thick, 80-100W enables fast cutting without carbonizing the edges.

For materials 5-8mm thick, the power needs to be increased to 120-150W, while the cutting speed is reduced (from 100mm/s to 50mm/s) to ensure clear cutting while avoiding overheating.

We have also developed an automatic power adjustment algorithm that automatically matches the optimal power based on material thickness (measured in real time by a laser thickness gauge).
Resulting in a 40% improvement in cutting quality consistency across materials of varying thicknesses.

Secondly, the accuracy of the motion system is crucial. The accuracy of laser cutting depends largely on the stability of the motion system.

The fifth-generation machine utilizes a dual-drive gantry structure (two synchronous motors on the X-axis), coupled with a high-precision ball screw (10mm lead, ±0.01mm positioning accuracy) and linear guides (≤0.005mm clearance) to ensure stability even at high speeds.

We use a laser interferometer (model: Renishaw XL-80) to precisely calibrate the motion system, maintaining an X/Y axis positioning error within ±0.02mm and a repeatability error within ±0.01mm.

In actual production, this accuracy translates into product edge flatness—the straightness deviation of a 900mm-long mouse pad’s edge is ≤±0.05mm, far exceeding the customer’s requirement of ±0.1mm.

Third, the vision positioning system is crucial. Poron material can undergo slight stretching or shrinking during the production process (especially for thinner models under 3mm). Relying solely on mechanical positioning can lead to cutting errors.

The fifth-generation machine is equipped with a 2-megapixel CCD vision positioning system. By capturing positioning marks on the material surface (such as pre-printed crosshairs), it calculates and compensates for deviations in real time.

We have also developed a “multi-marker positioning” algorithm, placing four positioning marks around the material.

Even with irregular material deformation, the system calculates the optimal cutting path through four-point fitting, reducing the error caused by deformation from ±0.2mm to ±0.05mm.

In the first quarter of 2025, a batch of 2mm-thick office mouse pads we produced had an overall deviation of 0.3mm due to stretching of the raw material.

With compensation provided by the vision positioning system, the final cutting error was still within ±0.08mm, achieving a product qualification rate of 99.7%.Process debugging is key to achieving high-precision laser cutting.

Through extensive experiments, we have established a parameter database for “material thickness – laser power – cutting speed – gas pressure” covering Poron material thicknesses from 2 to 8mm. Some key parameters are shown in the table below:

3. Reconstructing Industry Chain Value: Cost Transmission and Profit Distribution

The profit distribution of the Poron mouse pad industry chain exhibits a pronounced “smiling curve” pattern. The raw material supply chain holds the largest profit margin.

Rogers’ Poron material gross profit margin has consistently remained above 55%, while the gross profit margin of midstream processing is only 12-18%. This profit imbalance will be further exacerbated after polyurethane raw material prices rise in 2025.

Every 10% increase in upstream MDI prices will compress the profit margins of midstream processing companies by 3-4 percentage points, while having minimal impact on upstream material suppliers.

This unequal position in the industry chain has long placed domestic mouse pad manufacturers in a passive position.

Vertical integration has become a key strategy for companies to cope with cost fluctuations. Leading brands like Razer and Logitech have achieved partial raw material self-sufficiency through equity investments in upstream material companies.

In 2025, Logitech announced a strategic partnership with Wanhua Chemical to jointly develop polyurethane materials specifically for mouse pads, reducing its raw material procurement costs by 18%.

Domestic companies are also reducing intermediate costs through industry chain collaboration. For example, mouse pad manufacturers in Dongguan formed an industry alliance to jointly purchase Poron substrate, reducing procurement prices by 9%.

They also reduced inventory costs by 15% through shared warehousing and logistics systems. This collaborative approach effectively enhances the risk resilience of small and medium-sized enterprises.The trend toward localizing supply chains in emerging markets is accelerating.

In response to the rapid growth of the Southeast Asian esports market, leading domestic manufacturers have established assembly plants in Vietnam, adopting a “Chinese-made substrate + local assembly” model to avoid 30% import tariffs.

They have also adjusted the Poron material formula to suit local climate characteristics, adding anti-fungal additives to extend the product’s lifespan to 18 months in an environment with 85% humidity.

This localization strategy has yielded significant results. By 2025, the market share of domestically produced Poron mouse pads in Southeast Asia had increased by 9 percentage points year-on-year, reaching 41%.

Digital technology is reshaping supply chain efficiency. Leading companies are using blockchain technology to trace raw material sources, logging data from MDI procurement to finished product shipment, reducing quality traceability from 48 hours to 2 hours.

The widespread use of IoT devices has enabled dynamic inventory management. One company, using smart sensors to monitor Poron coil inventory in real time, has increased inventory turnover by 27% and reduced capital costs by 19%. These digital transformations not only improve supply chain efficiency but also provide data support for more precise responses to market demand.

4. Challenges and Opportunities: Policy-Driven Supply Chain Upgrades

Environmental policies are forcing the Poron supply chain to transition to a greener future.

The EU’s revised Chemicals Sustainable Development Strategy requires that all polyurethane materials contain at least 30% renewable content by 2030, posing a significant challenge to traditional Poron materials.

Driven by China’s “dual carbon” policy, the environmental costs of mouse pad manufacturers have risen significantly. Investment in VOCs treatment equipment has increased production costs by 5-8%. However, this pressure has also spurred innovation.

Rogers Corporation’s bio-based Poron material, which uses castor oil-derived polyols, reduces its carbon footprint by 58%. It has received EU EPEAT certification and commands an 8% price premium in the European market.

The battle over technical standards has become a new focal point in supply chain competition. China has issued a group standard for “High-Performance Polyurethane Mouse Pad Materials,” regulating 18 indicators, including material density and rebound rate.

Five key indicators reference internationally advanced standards while being adjusted to suit domestic conditions.

The implementation of this standard will help improve the quality consistency of domestically produced materials, with the product qualification rate for companies meeting the standard expected to rise from 76% to 92% by 2025.

However, the influence on international standards remains in the hands of European and American companies. Rogers led the development of six core indicators for the ISO standard for “Polyurethane Foam for Electronic Equipment,” which is currently being developed.

This could create new technical barriers to domestic material exports. Geopolitical factors are exacerbating the trend of supply chain regionalization.

Against the backdrop of Sino-US technological competition, China is prioritizing the localization of Poron materials, including it in its list of key “bottleneck” technologies. Related R&D investment is projected to increase by 45% year-on-year by 2025.

Furthermore, the implementation of the Regional Comprehensive Economic Partnership (RCEP) has reduced tariffs on Poron materials among ASEAN countries to zero, promoting regional supply chain integration.

This dual-circulation structure of “domestic circulation + regional circulation” is transforming the risk-based landscape of previous reliance on a single source of supply.

5. Conclusion:The future supply chain will exhibit a new form of “diverse symbiosis.”

On the one hand, international giants like Rogers are consolidating their high-end market share through technological iteration. Their third-generation Poron material, launched in 2025, boasts a compression rebound of 90%, continuing their industry lead.

On the other hand, domestic materials are gaining scale advantages in the mid- and low-end markets, with annual production capacity exceeding 8,000 tons, essentially meeting domestic demand.
Even more innovative is the “hybrid supply chain” model—high-end products utilize imported base materials to ensure performance, while mass-market products utilize domestic materials to control costs. This flexible configuration gives companies greater flexibility in market competition.

The restructuring of the Poron mouse pad supply chain is essentially a microcosm of the adjustments taking place in the global industrial division of labor.

From technological monopoly to diversified competition, from cost-driven to value-creating, from a single supply chain to an ecological network, every transformation of the supply chain drives industrial upgrading.

For domestic companies, the key to breakthroughs lies not only in catching up with material performance, but also in building an independent and controllable technological system and an efficient and collaborative industrial ecosystem.

With the maturity of new technologies such as bio-based materials and intelligent production.

The Poron mouse pad supply chain is expected to achieve a higher level of balance in environmental protection, regionalization, and digitalization, providing new impetus for the sustainable development of the global peripherals industry.

The ultimate winners of this industrial game will be innovators who master core technologies and adapt to the changing global landscape.