What is Die Cutting? Unfold All About
Die Cutting Process in Packaging
Bringing innovation and advancement in packaging is necessary to excel. Various techniques are good in this regard. However, die-cutting is exceptionally great in enhancing the custom packaging experience. If you are not familiar with this technique, no worries. Read on to learn what die cutting is. Also, unfold all about the die cutting process in packaging here.
The packaging world knows how to offer creativity with precision. This is the reason it is continuously excelling and meeting the demands of the ever-changing business landscape. For this, various techniques help to provide creativity and precision which is mandatory for effective outcomes. One of the popular techniques that enable both factors is die cutting. It is a crucial process to elevate the quality and functionality of any packaging. Whether it is elegant bakery boxes or sturdy packaging for various items, box die cutting can do wonders. This technique may appear strange to you if you listen to it for the first time. Well, you don’t need to rush here and there to understand it. This blog post is enough for you. It will demonstrate everything you need to know about die-cutting.
Understand Die cutting and Explore All About Die Cutting Process in the Packaging Industry:
Let's move ahead to a detailed discussion of the die cutting process. Also, learn related terminologies and the complete process associated with this technique.
What Is Die Cutting?
Die cutting is a technique that finds its deep roots in the printing and packaging industries. It allows both industries to accurately cut out different shapes from packaging materials using a die. A question may come to your mind here: what is a die? Die is a tool that is a basic component of this process. Having sharp blades, it is specialized for cutting and shaping various packaging materials using a press. Different dies for die cutting machines are famous.
Moreover, die cutting printing is also famous in the packaging industry and contributes to precision in die cut manufacturing. To correctly cut, ship, and print specific measurements, the role of die cut printing is remarkable. With its use, dieline is created. Dieline meaning is a printed layout that we follow for cutting. Thus, dielines are necessary from printing to crafting. They play an important part in avoiding errors in mass production. It serves as a template to guide the perfect die-cutting process using various die cut machines.
What Is A Die Cut Machine?
A machine that is used to create die cuts is called die-cut machine. Various metal die cutting machines make cutting jobs efficient and easy. Commonly, two types of die cutting machines are present: manual and digital die cutting machines. Featuring a crank, the manual die-cutting machine cuts various materials such as paperboard or cardboard. It has a custom metal die that helps cut shapes out of paper-based materials. When this die passes through the machine’s rollers pressure is generated that is used to cut out objects. Manual die cutting machines sometimes have motors that aid in the application of this pressure.
Digital die-cutting machines are in a more advanced form. Controlled by software, it offers ease of selecting shapes. It is attached to a phone, tablet, computer, or specialized cartridges that help the machine select and create custom shapes. It differs from manual die cutting machines because it lacks steel dies. There is a built-in blade inside the machine that cuts the shapes. You can use custom die cutting dies to cut your desired shape. There are many other Die cut craft machines that add convenience to the whole cutting process.
How To Use A Die Cut Machine?
For a manual die cutting machine follow the following simple steps to make custom die cut packaging.
- Choose your Material and Die to Create a Custom Shape You want. You can select paper, fabric, or metal based on your preferences and requirements.
- Prepare the cutting plates which are usually clear plastic. They are already a part of the manual cutting machines. Place your custom die with the cutting side facing up on the plate.
- Layer the materials on this plate. Place the second one on the material, creating a sandwich.
- Feed this sandwich to the machine's feed slot. Proper alignment is necessary to ensure accurate cutting
- Turn the crank of the manual die cut machine slowly. This action causes the shifting of the sandwich from the feed slot through the machine. Also, it results in pressure application on the die. This cuts the material into custom shape.
- Remove the cut shape from the outer edge of the material. Use this shape the way you like. You can create Custom die-cut boxes with the help of die-cuts.
To use digital die cutting machines, here is a simple guide:
- Prepare your design with the help of a phone, computer, or tablet. They should have compatible software with the machine. Adjust the design and specification according to your requirements.
- Load the material you want to cut on the cutting mat. The stickiness of this mat allows it to hold the material during cutting. Shift this mat with material into the machine.
- Select the settings that better suit your material types. Some machines can do this automatically.
- Send the die cut design to the machine using a USB connection, WiFi, or Bluetooth.
- Press the start button on the machine to die cut materials. Machine uses the design that you have selected to create the die cut.
- Unload the material and separate out the die cut from excessive material. Use the die cut for packaging.
Why Die Cutting Is Called So? A Brief History:
Die cutting originated in the 1300s when dies were used to cast or stamp metal coins. It is believed that this word comes from the Latin word “datum” which means given, put, or placed. Basically, the word die cutting means to cast or place. Till the 1800s, the word die was used to specify some things that were created by machines. Cut refers to creating a custom shape. Thus, die cutting explains the casting and cutting of customized shapes out of various materials.
The Die Cutting Process:
As the name indicates, this process is used for cutting. Besides this, it also includes many different functions.
- Scoring:
Scoring is a process in which an impression is imprinted on the material that has to be diecut. Also, indent or partial cut assists in guiding the accurate cutting process.
- Creasing:
This step creates a fold line on the surface area of the packaging material. By following this, constructing a box becomes convenient. Have you observed foldable boxes? They are famous for their ease of assembly. It is creasing over there that makes this job easy for all. Even a non-expert can do it on its own easily.
- Perforation:
Separating two pieces becomes easy with perforation. As the name signals it creates small holes on the surface and offers ease of tearing. Following the small cuts, a precise cutting is possible without using a blade or cutter.
- Through Cutting:
Cutting the material completely with perfection is the aim of this step. Remember that die cutting became famous due to the neat and appealing look it provides to the packaging. So, this function is very important to acquire the desired results you want. You can use a die cutter for accuracy. Thinking about what is a die cutter?
The choice of any of these functions depends on the different types of packaging materials and structural designs.
Considerations for Different Types of Die Cutting Process:
Different types of die cutting processes are used. All offer precision and ease to the users. However, selecting the one depends on two main factors. One is your specific needs and the other is your vision for your product. Below are some common types. Read them to develop an understanding so that you can make an informed decision.
- Blanking:
In this method of die cutting, a flat material is sliced by clipping from the exterior edge. This results in pieces having an accurate degree of flatness called blanks. They can be cut in any shape and size with precision. Most commonly, blanking finds its applications in the automotive, electronics, packaging, and aerospace industries. The reason behind the popularity of this type is due to its high accuracy and consistent quality.
- Drawing:
Drawing pulls various materials through the machine to a predetermined length. Thin and/or long sheets are the results of the drawing die cutting process. This technique is used to make complex metal parts. The reason is it helps to form accurate three-dimensional shapes.
- Forming:
This type is good for shaping raw materials on a curved surface. Most cylindrical parts of custom packaging result from the combination of forming with drawing. The beauty of this type lies in the fact it does not require any removal of material for creating custom shapes. For this, it involves stretching and bending.
- Coining:
To create an intricate look in your custom packaging, opt for coining. It makes circular holes in the material with the application of pressure. Also, it enables imprinting a design or shape into the material through high-pressure compression. Moreover, it also involves squeezing a material between two dies. This helps in creating details on the material.
- Broaching:
If none of the above methods is suitable then choose broaching. It can cut those materials that any other method can't. Broaching uses multiple rows of sharp teeth that cut materials with perfection. You can even use it to cut too hard or thick materials.
The above-narrated types are just a glimpse. Many other types are common in both digital and offset printing. Printing and die cutting are two aspects that can turn ordinary boxes into masterpiece custom boxes.
The Finishing Touch:
Besides printing die cuts, a finishing touch is good to polish the appeal of your die-cut boxes. The Custom Boxes offer many options to pick the one that better aligns with your preferences.
The purpose of these finishes is to bring forth luxury packaging that is hard to resist.
Final Thoughts:
In the packaging world, die cutting is an essential technique. It allows custom packaging manufacturers to achieve precision, versatility, and creativity. With this process, businesses can create product packaging designs that benefit them in many ways. Investing in this technique can earn you more customer flow and better sales. Gather necessary information from this article and make an informed decision that you will never regret.
FAQs:
What is die manufacturing?
Die manufacturing is the process in which a die is created using die makers and other tools. The resulting custom die is then incorporated into the press to form customized shapes.
What is a die used for?
A die is used for cutting custom shapes, patterns, and designs on packaging materials with precision.
What are die cuts?
Die cuts are patterns, designs, and shapes that are the result of the die-cutting process. Die cut examples include packaging boxes, cartons, labels, and tags.
How do you use die cuts?
To use die cuts in packaging, begin by folding and securing die-cut boxes along pre-scored lines. Attach die cut labels or tags using a tie or ribbon. Add die-cut embellishments to the packaging for a more customized packaging experience. For polished appeal, add decorations like bows or stickers are also important.
How to make die cuts?
To make die cuts use die cut cutters or die cutting machines.
What is a die cutting machine?
A machine that is used to create die lines using dies or blades is called die cutting machine. They come in various types. These include manual, digital, and electronic die cutting machines.
What Does Die Cut Mean?
Die cutting is a fabrication technique that involves cutting, shaping, and shearing stock material using specialized equipment and tools. It is used in printing to provide unique label shapes and designs.
What Does Die Cut Sticker Mean?
Die-cut stickers, also known as custom-shaped stickers, are cut to precisely match the shape of your unique design. These stickers are cut around the edge through paper and vinyl backing layers. Because of this, they are our most popular sticker option.
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