The printing and packaging industry is considered incomplete without die-cutting. Packaging companies hold proper machinery for the cutting of distinct shapes and sizes to fulfill the product requirements. The die-cut printing requires accurate product dimensions to cut the product packaging accordingly. Die-cutting ensures the cutting of the whole order in the same size as well as shape every single time. It gives a professional outlook to your design without making any compromise on the packaging measurements.
The following headings will help you learn more about the die-cutting process and its functionality in custom packaging:
Die-cutting is the process of cutting and shaping the packaging material using tools and machinery. Die is a sharp metallic object that perfectly cuts the same shape without even making the difference of an inch.
Die formation is the first step of custom packaging that is pressed into the selected packaging material to achieve the desired dimensions. The packaging manufacturers use custom steel dies and cutting machines to fulfill the required packaging order. This is most suitable for mass production and ensures size accuracy as well as precision in custom packaging orders.
The phrase “die-cutting” was started in the 1300s with the meaning of “placing or casting”. The process was initially started for the production of metal coins. The word “cut” represents the cutting of a specific shape in a predefined size with the use of “die”, representing the use of machinery.
The term “die cutting” was not very common till 1800 as it’s a method that originated from the shoemaking industry during the revolutionary era. It was meant to be the process of making accurate shoe sizes. Since the early days only used leather in the formation of shoes, which had to be cut by hand. The hand cutting often led to a change in size, resulting in erroneous shoe production.
The invention of die-cutting machines removed all such issues and gave the world an amazing concept of standardized shoe sizes.
There are two types of die-cutting machines available in the market:
Manual die-cutting machines utilize pressure to cut the packaging materials efficiently. Metal dies are made according to the required shape and size to pass through the machine rollers. Pressure is applied to achieve accurate dimensions. The packaging manufacturers use motors to apply pressure onto the packaging material.
Digital die-cutting machines are operated using the software. They hold no specific requirement for the steel dies but rather have a sharp blade within the machinery to cut through the packaging material to achieve accurate dimensions. The shape is created using computer software, a phone, or a tablet to instruct the machine to carry out the packaging material-cutting procedure.
The die-cutter could be easily understood by a cookie-cutter, which is pressed into the cookie mixture to create accurate cookies. Similarly, the die cutter is pressed into the packaging material to achieve the desired dimensions.
Technological advancements have made the die-cutting procedure quite accurate and offer die-cut packaging boxes the required precision. Computer-aided design (CAD) software is used for the digitalized creation of die-lines. A die-line in packaging is a framework required to draw precise outlines on wooden die boards using laser cutting machines. This is necessary to achieve accuracy in custom packaging order production.
Die boards could be generated accurately by properly mapping the cut lines, crease lines, bleed lines, and safety zones. The die-cutting operates on the following mentioned distinct functions:
· Through cutting: cut through the packaging material.
· Scoring: partial cutting on a specific area
· Creasing: make folding lines for easy packaging production.
· Perforating: small cuts for effortless tearing
Every function works differently for distinct types of packaging materials and designs. Creasing is considered best for the creation of corrugated packaging.
In the era of incredible technological advancements, manual die-cutting machines are still the best for the mass production of custom packaging orders. Following are the different types of die-cutting techniques used in the packaging industry:
Flatbed dies are rectangular pieces of flat die board that hold specific shapes for the manufacturing of customized packaging. The process uses a flatbed machine to hard press the die-cut into the cardboard material.
The flatbed dies are quite small in size; therefore, they are not recommended for large packaging designs. These are small dielines and are preferred for adding detail to the designs with small and tight cut-outs.
Rotary die cutting is the cylindrical press rolled around the packaging material to achieve the defined dimensions for the custom packaging order. This is quite a quick process and is considered best for mass packaging production.
The rotary die cutters are quite efficient in performing two distinct functionalities at one point in time. The brand could choose any finishing method from UV printing, embossing, debossing, and foil stamping to enhance its packaging excellence.
The digitalized die-cutting process uses software to accurately cut the packaging material without using any type of die. The digital devices are used to give the selected packaging material the desired dimensions. This type is suitable for small projects but becomes expensive for mass production.
The software is used to define the shape and size of the custom packaging order. The digital cutting machines hold a sharp blade to cut through the packaging material according to the accurate product dimensions.
Die-cutting is a versatile tool used to cut packaging materials according to the accurate size and shape. They leave no room for error and keep the packaging consistent by repeating the procedure. The use of die-cutting makes the whole packaging process precise while allowing the retailers to get the packaging produced in bulk whenever they need to enjoy great discounts.
Box Agency puts its best efforts into keeping the die-cutting process unproblematic for valuable clients. We hold an amazing team of professionals working diligently to give your packaging dreams a realistic touch. We specialize in making cardboard, corrugated cardboard, and other packaging materials quite attractive using the die-cutting process.
So, what are you waiting for? Contact us and discuss your required custom packaging order to achieve nothing less than brilliance. We hold a wide range of designs, printing techniques, and finishing methods to efficiently transform your packaging imagination into eye-catching product packaging.
![How Tall is A Box of Cereal? [Cereal Box Dimensions]](data:image/svg+xml;base64,PHN2ZyB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciIHdpZHRoPSIzMDAiIGhlaWdodD0iMTk1Ij48cmVjdCB3aWR0aD0iMTAwJSIgaGVpZ2h0PSIxMDAlIj48YW5pbWF0ZSBhdHRyaWJ1dGVOYW1lPSJmaWxsIiB2YWx1ZXM9InJnYmEoMTUzLDE1MywxNTMsMC41KTtyZ2JhKDE1MywxNTMsMTUzLDAuMSk7cmdiYSgxNTMsMTUzLDE1MywwLjUpIiBkdXI9IjJzIiByZXBlYXRDb3VudD0iaW5kZWZpbml0ZSIgLz48L3JlY3Q+PC9zdmc+)
