What Is Die Cutting? Process, Types & Uses in Packaging and Stickers

Die cutting is a printing and packaging process through which materials are cut into custom shapes. In this process, a shaped tool known as a “die” is used to cut paper, cardboard, vinyl, label, and other packaging materials.

This cut material is then used to create custom boxes, product labels, stickers, hang tags, window cutouts, and more. In this guide, we’ll take a look at what is die cutting in detail, how the die cutting process in packaging works, and when to use it for custom packaging and stickers.

What Is a Die Cut?

A die cut is a shape that comes as a result after a material sheet is passed through the die cutting process using a die. This die is a custom-made tool with sharp blades that press into the material and cut it into the desired shape.

Die Cut vs Dye Cut

The correct spelling is die cut, not “dye cut.”

• Die means the metal cutting tool used to cut the shape on packaging material.

• Dye means a coloring substance such as a fabric dye.

Often, people confuse “die” with “dye” when searching for “die cut”. The correct term in printing and packaging is die cut.

What Is a Dieline?

A dieline is an unfolded, flat layout of the packaging or a sticker before it is die cut. A dieline shows:

• Cut lines

• Fold lines

• Glue tabs

• Bleed areas

• Safe zones

• Window cutouts

• Business card slits

A good dieline helps prevent mistakes before the job goes to print.

How the Die Cutting Process Works

In this process, the packaging is transformed from a flat sheet of material into a custom shape or box. It is more than just cutting. It includes design, tooling, cutting, and finishing.

Step 1: Create the Design

First of all, you have to decide upon what you want to create. Is it a custom box, a sticker or label, a hang tag, or a mailer?

Don’t forget to consider:

• Product size

• Material type

• Shape

• Number of colors

• Where the folds will go

• Whether the package needs a window or tear strip

Step 2: Prepare the Dieline

After determining the points mentioned above, create a dieline fit for your packaging or sticker.

The dieline of both of these vary a lot. For boxes, it highlights panels, flaps, glue tabs, and fold lines. And for stickers, it shows the boundary of the sticker.

Step 3: Make the Die

The printer creates a custom die based on your packaging dieline. The die might include:

• Cutting rules for the outside shape

• Creasing rules for folds

• Perforating rules for tear lines

• Cutting rules for windows or holes

Step 4: Set Up the Material

The material is then precisely put into the die cutting machine. This is done to make sure the die is in the ideal position to make the cut on the printed material.

Step 5: Cutting the Material

The die then presses into the material and cuts it into the shape. After cutting, the extra material that is left around the die cut part is waste.

Step 6: Remove the Material Waste

The finished pieces are separated from the waste material. Then they usually go through the final steps such as folding & gluing and packing. Lamination, foil stamping and embossing happen earlier, on the printed sheet before it's cut. 

For boxes, the die-cut blanks are folded and glued into finished cartons. For stickers and labels, the finished pieces are removed from the backing paper or liner.

Die Cutting Has Many More Uses

Die cutting can also help to create folds, tear lines, windows, and raised designs on the dieline template.

• Scoring (or creasing): The die creates a shallow line that allows the packaging to be folded or bent easily.

• Perforating: It makes tiny micro-cuts in the dieline, making it easy to tear a specific part of the packaging.

• Embossing and debossing: Embossing raises the design elements, while debossing recesses them to make logos and brand names stand out.

Types of Die Cutting

Below are the classifications of die cutting that are the norm in the packaging industry.

Flatbed Die Cutting

This die cutting process uses a flat press and a steel rule die. The material is placed on a flat surface, and the die presses into it to cut it into shape.

This method is ideal for die cutting:

• Folding cartons

• Rigid paperboard

• Thicker materials

• Custom boxes

Rotary Die Cutting

The rotary die cutting process uses a cylinder-shaped die. In this process, the material moves through the machine and die rolls over it to cut it into shape.

This method is ideal for cutting:

• Labels

• Stickers

• Films

• Tapes

• Long rolls of material

Laser Die Cutting

The laser die cutting process is done by using a laser to cut the material. It doesn’t require a physical steel rule die. This makes it useful for prototypes, detailed designs, and short runs.

This method is ideal for:

• Custom stickers

• Detailed paper designs

• Short runs

• Prototypes

• Complex shapes

Digital Die Cutting

The digital die cutting process is done through a small blade which is controlled by a computer. Just like the laser cutting process, this one also doesn’t require a custom steel rule die.

Die Cutting Process in Packaging

Die cutting is one of the foundational steps in creating custom packaging. It cuts and creases the flat printed sheet to transform it into a box layout ready for assembly.

Custom Product Boxes

Die cutting helps create custom product boxes in many shapes and sizes. It can cut the box outline, fold lines, tuck flaps, and glue tabs in one press stroke.

Custom boxes can include:

• Tuck-end boxes

• Sleeve boxes

• Rigid boxes

• Folding cartons

• Display boxes

• Product boxes with inserts

Mailer Boxes

Mailer boxes are a popular option for e-commerce brands. The die cutting process helps to create the box shape, fold lines, tabs, and closures.

A custom mailer box includes:

• Custom inserts

• Tear strips

• Window cutouts

• Unique closures

Window Cutouts

It is a hole that is die cut in the box structure that lets customers see the product inside.

Window cutouts are common for:

• Food packaging

• Cosmetic boxes

• Toy packaging

• Gift boxes

• Retail packaging

Hang Tags and Product Tags

The die cutting process has the potential to create custom hang tags in any shape.

A custom tag can include:

• Brand logo

• Product details

• Price

• QR code

• Social media handle

• Care instructions

Custom Inserts

Another use of die cutting is that it can be employed for cutting the inserts in exact product shapes to hold them inside the boxes.

Pouches & Flexible Packaging

The die cut process is ideal to create flexible packaging in custom shapes. This includes pouches, sachets, and labels.

Die Cutting Process for Stickers and Labels

Die cutting is the important process for stickers & labels. It helps brands create shapes that match their logo and product.

Custom Die Cut Stickers

A custom die cut sticker is cut to the exact shape of the design. It could be a sticker shaped like a coffee cup, animal, flower, or logo cut with a custom die.

Custom die cut stickers are great for:

• Product packaging

• Event giveaways

• Brand promotions

• Laptop and water bottle decals

• Retail displays

Product Labels

Die cutting helps labels fit the product better. A product label can be shaped to follow the bottle, jar, can, or tube curve.

Bottle & Jar Labels

These labels need to be made in custom shapes to fit around curved surfaces. The die cutting process can help to create labels that fit on bottles and jars.

Sticker Sheets & Kiss Cut Stickers

A kiss cut sticker is cut through the sticker material but the backing paper stays intact. This lets customers peel the sticker off easily.

Sticker sheets can include several shapes on one sheet.

How to Create Die Cut Ready Artwork

A good artwork can help to prevent costly mistakes that usually occur due to die cutting. Follow the steps below to make your dieline perfect for die cutting.

Use a Printer-Provided Dieline

Print247 experts are here to provide you with a dieline template that highlights the cut, fold, bleed, and safe zone.

Add Bleed

Think of the bleed area as the extra that doesn’t affect the significant design elements. Add at least 0.125 inch of bleed on all sides.

Keep Text Inside the Safe Zone

Make sure the significant details on your artwork like text, logos, and product info stays away from the cut line by 0.25 inches.

Conclusion – Get Custom Die Cut Packaging and Stickers from Print247

The die cutting process helps plenty of brands to create packaging, custom pouches, labels, and stickers that match their brand vision. From custom boxes to cardboard mailers, labels to bottle stickers, hang tags to backing cards, die cutting transforms a simple material sheet into custom branded packaging and printing materials.

At Print247, we help businesses to create custom die cut boxes, custom die cut stickers, custom labels, hang tags, mailer boxes, and product boxes according to their brand requirements. Discuss your packaging and sticker customization needs with our experts and they are sure to help you create unique designs for your packaging. If you have a design of your own, then upload it to our order form and we’ll show you how it looks.

We’ll send you the online design proof and only after your approval we will begin the production. Our MOQ of custom printed die cut packaging and stickers is 1,000 pieces. Our customer support is just a phone call away if you want to personalize boxes according to your industry needs. We offer free shipping in the USA for all custom die cut packaging and sticker orders.

Give us a call now at +1 (832) 807-3429 or send an email to support@print247.us.

FAQs

What is die cutting?

Die cutting is a process that uses a die to cut materials into custom shapes.

Is it “die cut” or “dye cut”?

The correct spelling is die cut. “Dye cut” is a common misspelling because “dye” and “die” sound the same.

What is the difference between die cutting and laser cutting?

Die cutting uses a physical die to cut the material. Laser cutting uses a laser to cut.

What is the difference between die cutting and scoring?

Die cutting cuts through the material. Scoring makes a shallow line that helps the material fold cleanly.