Die cutting is a process that uses specialized machines and tools to cut, form, and shear stock material into shapes. Think of it like a cookie cutter, but for all kinds of materials. It involves a die, a piece of metal tooling that cuts specific shapes out of the material. The excess material, called the ‘matrix,’ is removed. You’ll often see the ‘die line’ in your proofs as a thick colored line.
Types of Die-Cutting Processes
Die cutting comes in various forms, but three major processes are particularly relevant for labels and other materials: flatbed, rotary, and semi-rotary die cutting.
Flatbed Die Cutting
Flatbed die cutters use hydraulic presses and other lifting systems to press a die down on a sheet of material. This method is generally used for low-volume projects and larger products. Flatbed die cutting is more suitable for heavier materials such as plastics, foam boards, and wood rather than most label stocks.
Rotary and Semi-Rotary Die Cutting
Rotary and semi-rotary die cutters use rollers to pass long, flexible sheets of material through a machine, where a rolling die attached to a magnetic cylinder makes the cuts.
Semi-rotary die cutting works well for labels due to its efficiency. The cylindrical die rolls in one direction, while the press moves the web back and forth, allowing a single cylinder to make multiple cuts.
Materials for Die Cutting
- Corrugated: Ideal for sturdy packaging solutions.
- Folding Carton: Perfect for creating custom packaging.
- Solid Board: Great for durable and high-quality prints.
- Foam: Used in various applications for cushioning and protection.
- Wood: Offers unique and intricate designs for special projects.
- Plastics: Suitable for a range of products, from packaging to promotional items.
Considerations for Designing Die Cut Projects
Designing for die cutting involves several important considerations to ensure the final product meets your expectations. Here are some tips to keep in mind:
- Avoid Sharp Corners: These may tear when the matrix is removed, leading to unnecessary waste.
- Space Around Holes: Ensure there’s enough space between the edge of your design and any holes. Thin strips of material are prone to tearing during removal.
- Add a Bleed Area: Extend your design artwork at least 1/16” past the edges to prevent accidental white spaces.
- Correctly Add Die Lines: In your Adobe Illustrator file, mark the die line as a specific spot color and as a joined line on its own layer.
Why Understanding Die Cutting Matters
Knowing the basics of die cutting can make your job easier and improve communication with your printer. Whether you need standard shapes or custom designs, understanding the process helps you get the best results. This knowledge is essential for labels and a wide range of materials and applications.
For more information and expert guidance, contact our Innvoke team.