Views: 0 Author: Daria From Grace Grass Publish Time: 2025-05-27 Origin: Site
In the gym turf industry, one of the most common concerns we hear from customers is about uneven edges and visible gaps between joined turf rolls.
These imperfections are often caused by manual cutting methods, where hand tools like utility knives are used without precise guidance. To solve this issue once and for all, we’ve developed a new cutting solution that ensures clean, straight, and consistent cuts—especially for turf with integrated pads.
Crooked or wavy edges
Frayed fibers due to dull blades
Gaps when rolls are joined together
These flaws not only affect the appearance of the gym but also reduce the overall durability of the installation.
Currently, the primary method used in the market for cutting is still manual operation. However, no matter how sharp the blade is, without proper positioning aids or cutting guides, it's easy for human error—such as an unsteady hand—to result in uneven or inaccurate cuts. This issue is further compounded by the thickness of padded gym turf, which requires significant force to cut through using standard utility knives. The blades tend to wear down quickly, and due to variations in workers' strength and skill levels, it becomes extremely difficult to ensure consistent, clean, and precise cuts every time.
Of course, there are various types of cutting machines available on the market. However, most of these machines are limited in terms of the size of material they can handle, and thus are not suitable for our large-format gym turf rolls. This presents a significant challenge: our product cannot be processed using light-assisted or precision-cutting machines designed for smaller materials. Additionally, considering the relatively low order volume of this product category, investing in such specialized equipment is economically unfeasible for most factories.
Furthermore, gym turf products typically incorporate functional design elements such as lines, patterns, logos, and numbers. Existing cutting machines lack the flexibility to dynamically adjust the cutting path in real time. As a result, if the turf roll is even slightly misaligned during processing, these critical visual elements may be cut inaccurately or damaged, leading to a high risk of product waste and customer dissatisfaction.
We've replaced the traditional hand-cut method with a custom-designed track system and electric rotary shear. This cutting method guarantees perfectly straight, clean edges—every single time.
Our custom track system with a mounted electric rotary shear.
We begin by unrolling the turf and laying it flat on the ground. Using the design drawing as reference, we employ a laser level to project a perfectly straight line along one edge of the turf. This laser line serves as the foundational guide for the entire trimming process, ensuring all subsequent cuts remain aligned and accurate.
Laser level in action to guide the first edge cut.
Once the cutting position is determined with the laser level, we use a chalk line to snap a precise, visible cutting guideline along the turf. This step provides a clear visual reference for both manual positioning and machine-guided trimming.
Snapping a chalk line for accurate cutting.
To create a perfect 90° angle for edge joining, we use a right-angle ruler to measure and mark the perpendicular cut line. This ensures that when two turf rolls are joined, the edges align seamlessly and squarely.
Measuring and marking the perpendicular edge.
For added precision, we stretch a diagonal line from corner to corner of the turf. This step serves as a cross-check to confirm the squareness of the layout and helps identify any skewed or misaligned sections before cutting begins.
Diagonal line check for layout accuracy.
Here's where our process stands apart. We've developed a custom rail track system equipped with fixed guide slots that securely hold an electric circular cutter. Once the track is aligned with the chalk line and pressed firmly into place, we activate the cutter and glide it smoothly along the track. The result is a flawless, clean edge—every time. No more uneven cuts, hand slips, or frayed turf.
Circular cutter on track for clean, consistent cuts.
Comparison: Traditional manual cutting vs our electric shear method.
When two turf rolls trimmed with our method are joined together, the seam is tight and nearly invisible. No large gaps, no overlaps—just a smooth, professional finish.
Perfect seams = better appearance
Fast, accurate installation = saved time and labor
No fraying or tearing = longer product life
Professional quality = happy clients & repeat business
Whether you're a distributor, installer, or gym owner, we're here to make sure every turf roll fits perfectly.
Contact us to learn more or request a sample of our precision-cut gym turf!
