There is cutting method which is commonly used to provide a particular shape to materials, is known as die cutting. This process is suitable for various materials including paper, cardboard, fabric, foam, leather, plastics and almost every other material. The application of die cutting is in many sectors including packaging, printing, clothing, and crafting, and a common feature is that it allows designers to achieve unique shapes and motifs.
If you’ve ever seen anything relating to intricate packaging, shaped labels or creative crafts, you’ve seen die-cut items. Now it is time to explain what all those terms actually mean and how die cutting works with example of its usage.
What is Die Cutting?
Die cutting is where a predetermined shape or pattern is cut onto a material by a die cutting machine. The material is pressed between two electrodes which have a sharp, flat blade or “die” to form the shape on. The die is mainly of metal and are prepared to suit the design or shape of the particular project to be undertaken.
Die cutting meets tight tolerances and consequently provides excellent repeatability which ideal to intricate and precisely shaping, making it ideal for high volume manufacturing. Die cutting is a versatile way of achieving customized designs, especially to make an irregular or difficult shape in a wide range of applications such as product packaging to shaped greeting cards, for examples .
What does die cut means in the die cutting process?
Die cut as a term means any material that is produced using the die cutting process. Briefly, if a material is to be cut through a die cutting machine, the die cuts shapes or form designs on the material by stamping or punching it. The final product is hence a “die cut”, and can be used for product packaging, for promotional item or any customized design required by the particular product.
For instance, in the packaging business, die cutting is employed to manufacture packaging cartons with fine, sharp and well aligned scores and also the accurate location of flaps. By die cut here refers to the section or portion in the cardboard or paper that have been cut in a specific shape to make a box set.
How Does Die Cutting Work?
Die cutting has a few stages, though the exact number may well depend on the intricacy of the shape being cut and the kind of die cutting machine used. Here’s a simplified breakdown of the die cutting process:
- Design Creation: The first is obtaining a design on which the die cut is going to be used on to make the appropriate shape. The design is usually developed online employing graphic design software or elevating templates. After getting approval of the design, the design is converted into a metal die.
- Die Production: A die is normally specially carved out of metal in the form of the design desired. The die has cutting edges that will stamped on or cut the material to the required shape.
- Material Placement: In most cases, material to be cut, such as paper, cardboard, fabric, etc. is put on the die cutting machines. The material can be in a sheet form or even roll form depending on the configuration of the plastic machine.
- Cutting Process: The die cutting machine applies pressure to the die which shapes the matter to have the right cut out shapes. This machine cuts all pieces rationally making sure that they are symmetrical in size and form. The material may be cut through to certain points or not depending with the cuttings required in the design.
- Finishing Touches: Afterward all the newly formed extra materials is cut away. These simple die cut pieces re available for folding or gluing upon which they are ready to be assembled.
Types of Die Cutting
Die cutting is classified into several categories based on the kind of end product achieved and the kind of material to be cut. The two most common methods are:
- Flatbed Die Cutting: This method employs a flat die and it is most preferably used when the laminate is thick such as cardboards and foams. It gives clean cuts and is especially suitable in intricate patterns.
- Rotary Die Cutting: In rotary die cutting the die is placed on the cylinder that rotates and hence the name rotary. This method is used for high-speed production of materials: up to 0.5 mm thick, for the production of labels, films or fabrics.
Benefits of Die Cutting
Several benefits accrue to using die cutting to modify material, thereby making it highly desirable to manufacturers, designers and other business entities. Here are a few key benefits:
- Precision and Consistency: Die cutting is highly accurate and ideal as a means of achieving an intricate as well as quality end product each time it is accomplished. This is especially important for companies that are in business of manufacturing products such as packaging where every box must be the same standard size and shape.
- Customization: This is because die cutting enable business people to cut out very complex designs, shapes and patterns to fit certain requirements of a business. This can be good as an exposure and come up with packaged products that separate them from the rest.
- Efficiency: The process is very efficient with large volumes hence ideal for bulk packagers and firms in large production of promotional items.
- Versatility: Many types of material is suitable to die cutting such as paper, fabric, foam, plastic, and even metals. This makes it an ideal process for almost all industries as it establishes how different industries can adopt the process.
Applications of Die Cutting
Die cutting is used in many industries, including:
- Packaging: People opt to use customised boxes, envelopes and other packing requirements.
- Crafts: Card making, scrapbooking, decorative art, etc.
- Printing: Made business cards, stickers, souvenirs and other company related products.
- Textiles: Clothing or industrial fabrics in form of shapes.
- Labels: Bottle and product shaped labels.
Conclusion
Die cutting as a versatile and efficient manufacturing to adopt to make exact kinds of shapes from different materials. From complex labeling to fancy shapes, die cutting brings the opportunity to improve the looks of your business assets and their packaging.
