Die cutting is a common term in label printing, often mentioned when dealing with uniquely shaped packaging or intricate logos. While you don’t need to be a die cutting expert – that’s our job – understanding the basics can help you know what is possible. Below is an overview of the die cutting process, its meaning, and key considerations for designing custom-shaped labels.
What is the die cut definition? Die cutting is a fabrication process that uses specialized machines and tools to convert stock material by cutting, forming, and shearing. In printing, die cuts are used to create custom shapes and designs for labels.
It starts with a part called, unsurprisingly, a die. A manufactured die is a specialized metal tool designed to cut specific shapes from materials, much like a cookie cutter works on dough. Instead of cookies, it cuts label material, leaving behind excess material known as the "matrix." The "die line," typically shown as a thick colored line in proofs, indicates where the die will cut.
Die cutting varies in methods, with some being more suitable for labels than others. The three primary processes to consider for custom labels are flatbed, rotary, and semi-rotary, which we’ll discuss below.
Flatbed die cutters use hydraulic presses or lifting systems to press a die onto a sheet of material. This method is typically used for low-volume projects and larger-sized products. Flatbed die presses are better suited for heavier materials over 1/8” thick, such as felt, fiber, fabrics, and metals, rather than most label stocks.
Both rotary and semi-rotary processes use rollers to feed webs—long, flexible sheets of material—through a machine, where a rolling die on a magnetic cylinder cuts the material. Semi-rotary is often better for cutting labels due to its efficient design. In semi-rotary cutting, the cylindrical die rolls in one direction while the press moves the web back and forth, allowing a single cylinder to make multiple cuts. This reduces the number of web passes, enabling faster completion of complex cuts and quicker turnaround times. After cutting, the excess material is removed, leaving only the finished labels.
Semi-rotary and rotary die cutting machines can use either solid or flexible dies. Solid dies are steel cylinders with built-in designs, while flexible dies are thin steel sheets that wrap around magnetic cylinders. Flexible dies are more cost-effective, making them ideal for businesses needing custom dies for labels.
Die cut labels are custom-cut labels that are cut to the shape of a design. They can be used for a variety of purposes, such as on jars, tubes, hang tags, and collars.
The die cutting process varies depending on your needs, with your design playing a significant role. Standard dies are readily available for typical shapes like circles and squares. However, for custom shapes or intricate design elements, it’s essential to work with a label converter experienced in die cutting.
When designing your label, keep these tips in mind:
- Avoid acute angles and sharp corners, as they can tear when the matrix is removed, leading to unnecessary waste.
- Leave enough space between the label edge and any holes to prevent thin strips of material from tearing during removal.
- Include a bleed area by extending your artwork at least 1/16" beyond the label edges to avoid accidental white spaces.
- Properly add the die line to your file, marking it as a specific spot color and a joined line on its own layer.
