Die-cutting

Die-cutting is a finishing and printing process that involves cutting specific shapes out of materials such as paper, cardstock, cardboard, foil, or plastics. It is used whenever traditional straight cutting (e.g., using a guillotine) is insufficient—for instance, in the production of complex packaging, puzzles, stickers, or cards with unusual shapes.

Key elements of the process

The primary tool used in this technique is the die. It typically consists of a special board (e.g., made of plywood) into which blades, bent to the required shape, are embedded and secured. In addition to cutting blades, the die may include other elements:
  • Creasing rules: These do not cut the material but instead press indentations (crease lines) into it, facilitating neat folding of the cardboard later on.
  • Perforating rules: These create a series of small cuts, allowing a section of the material to be easily torn off (e.g., a ticket stub).
Step-by-step process
  1. Design and die preparation: Based on the graphic design, a die is created that reflects the desired outer shape and fold lines.
  2. Loading the material: A sheet of paper or cardboard (often already printed) is fed into the die-cutting machine (commonly referred to as a die-cutter or platen press).
  3. Die-cutting (pressure): The machine presses the die against the material with great force. Under this pressure, the blades cut the edges, while the creasing or perforating rules impart the necessary structural features.
  4. Stripping (waste removal): After die-cutting is complete, the excess material (known as the skeleton or matrix) is removed, and the finished cut pieces are packed or sent for further processing.
Main die-cutting methods
  • Flatbed die-cutting: The most common method, in which the die moves vertically (up and down), pressing against a flat sheet of material resting on a base. Ideal for corrugated board, heavy paperboard, and medium-sized production runs.
  • Rotary die-cutting: Uses cylindrical cutting forms that rotate while the machine is operating. This is a very fast method, used primarily for high-volume production (e.g., manufacturing self-adhesive labels from a roll). It is often combined with prior flexographic printing.
Applications of die-cutting
  • Packaging: Cardboard boxes and cartons, solid board boxes and packaging, laminated (litho-laminated) packaging and boxes, most packaging types listed in the FEFCO catalogue, and cartons for cosmetics, pharmaceuticals, or food products (e.g., pizza boxes).
  • Advertising and office materials: Presentation folders with pockets, custom-shaped calendars, door hangers, notebooks, and leaflets with rounded corners.
  • Paper-based accessories: Greeting cards with intricate cut-out designs, puzzles, board games, and self-adhesive labels.