What is Die Cutting?

Die Cutting cut custom forms and designs from paper, cardboard, fabric, and metal. To form the material, a die with sharp blades is used. Die Cutting by custom pack box is used to make custom packaging, labels, and products.

What is a Die in the Packaging Industry?

A die is a metal instrument used in packaging to cut, shape, and form paper, cardboard, and other materials into specific shapes and sizes. Packaging dies are usually adapted to the design or form.

Die cutting, embossing, and foil stamping are packaging production methods that require dies. They are vital for designing custom packaging that stands out on store shelves and protects products during transport and storage.

Die-cutting machines: manual and digital

Both manual and digital die cutting machines exist. Crank-driven manual die cutting machines cut material. The rollers press the metal die to cut the paper to its shape. Manual die cutting machines may have motors to impart pressure.

Software controls digital die cutting machines. They don’t need steel dies because the machine’s blade cuts the shape. Software chooses the shape and creates it on a computer, phone, tablet, or machine cartridge.

History of Die-Cutting ~ Why it was named die-cutting

Die cutting originated in the 1300s from the middle English term ‘de’, thought to be from the Latin word “datum” for “given” and “put or placed”. Place or cast is die cutting’s root. Dies were mostly used to cast or print metal coins in the 1300s.

In the 1800s, mass-production of similar-sized and-shaped products began, and “die” was used to indicate that they were “created by machines”.

Cut means making a particular shape, and die cutting means casting and cutting.

Die cutting was first employed in the 1800s to make more accurate shoe measurements. Since shoes were made of leather, the bottoms had to be cut by hand, which was painstaking and often resulted in misfitting shoes. When the die cutting machine was introduced, shoes could have regular sizes, which we now take for granted.

Manual and Digital Die Cutting Machines

Die-cutting machines cut paper, cardboard, leather, and other materials with dies. Digital and manual die-cutting machines are the major types..

Manual Die-Cutting Machine

A manual die-cutting machine is laborious. The user turns a crank or lever to feed material and die through the machine.

Although manual machines are cheaper and easier to operate, they may not be ideal for larger or more complex projects.

Digital Die-Cutting Machine

Digital die-cutting machines design and cut forms with software. Computer users develop designs that are delivered to the machine for cutting.

Although more expensive and requiring computer expertise, digital machines offer better precision and diversity in cutting forms and designs.

How Does Die-line Template Affect Die-cutting?

In the packaging industry, a dieline template is needed before die-cutting any package material.

Adobe illustrator can simulate your die-cut plate’s format, helping you see it.

Dielines define packaging box shape and size before die-cut printing.

Your custom packaging may need a custom die-line template due to its shape, size, or other requirements.

Read our blog to learn more about die-line and how to develop a template. Dielines are needed before embossing, debossing, or UV coating packaging.

Process of Die-Cutting

Manufacturing uses die-cutting to shape and size materials. The steps of die-cutting are:

Designing and making die: Die-cutting machines shape and cut materials. Die design depends on material shape and size.

Material selection: Thickness, stiffness, and flexibility determine the cutting material. Common die-cutting materials are paper, cardboard, and corrugated cardboard.

Material preparation: To prepare the material, trim it to size and shape. This ensures material fits in die.

The die is mounted on a die-cutting machine. After setting the die, the material is added.

Cutting the material: The die-cutting machine cuts the material to size and shape. Cutting can be repeated to attain the desired outcome.

Any surplus material not part of the final product is removed from the cut material.

Quality control: All cut materials are checked for standards. Corrections are made to any errors.

Packaging: Cut material is packaged for shipment or processing.

Die-cutting is a precise and efficient procedure used in many sectors to make packaging, labels, and other specialized items.

Can I Make My Own Metal Dies?

Yes, you can. We advocate using packaging specialists to create metal dies because you may make a mistake.

What Are Cutting Pads or Plates?

Die-cutting pads or plates provide a surface for the die to cut. These robust objects are usually composed of metal and vary in size and thickness. Die-cutting projects require accurate and clean cuts with cutting pads or plates.

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What is Die Cutting
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What is Die Cutting?

Die Cutting cut custom forms and designs from paper, cardboard, fabric, and metal.