Die - what is it?
The process of making die cuts begins with a die, which is a metal object with sharp edges.
Essentially, a die is like a cookie cutter in that the shape of the metal object is the same shape cut out of the material. Die types vary. Steel-rule dies, for example, are extremely sharp but are protected by plastic or foam.
Steel-rule can be used to cut stacks of less-thick Packaging at the same time or to cut thicker packaging materials. Thinner metal dies cannot cut very thick material because they're not as sharp. Die sets of this type are lighter and easier to store, and they do not have foam or plastic surrounding them to ensure their safety.
Die-Cutting Machines, both Manual and Digital.
A manual die-cutting machine and a digital die-cutting machine are used for die-cutting. In manual die-cutting machines, the material is cut by turning a crank. Through the machine's rollers, the metal die cuts out the shape of the paper based on its shape. Motors on manual die-cutting machines may also apply this pressure.
Software controls are digital die-cutting machines. A blade within the machine cuts the shape, so steel dies aren't needed. A computer, phone, tablet, or even a specialized cartridge can be used to create that shape using the software.
Why is Die Cutting Called Die Cutting?
In the 1300s, the phrase 'die cutting' arose from the Middle English word 'de,' believed to derive from the Latin word' datum,' meaning 'given,' 'put,' or 'placed.'
The root meaning of die cutting is placing or casting. Die-casting and coin-stamping were the main uses of dies during the 1300s.
It wasn't until the 1800s that mass-production of items of a similar size and shape became common, and the term "die" was used to specify that it was machine-made.
A cut is a custom shape, and die cutting is the casting and cutting of shapes.
In the 1800s, die cutting was used to create more accurate and precise shoe sizes. The leather shoe soles were cut by hand, a tedious process that often resulted in mistakes and ill-fitting shoes.
The die-cutting machine's invention made it possible for shoes to have standard sizes (something we often take for granted).
A Die Line's Role in Custom Die Cutting
It's important to outline what needs to be cut before making a die cut on any printed material. Dielines play an important role in custom die cutting.
Dielines are used in die-cut printing to outline the shape and size of packaging boxes before cutting occurs.
With so many different shapes in the packaging world, a custom packaging manufacturer can cut any shape out of any material.
Please read our guide to learn more about setting a deadline for your Packaging and printing project. You'll need a die line before you can finish your Packaging with matte or gloss lamination, embossing or debossing, or UV coating.
What To Consider When Choosing A Die-Cutting Process
Die-cutting can be done in a variety of ways. It depends on your specific requirements and your vision for the product which one you use. The following are some of the most popular methods:
- Blanking: Blanking involves slicing flat material from the outside edge, making it look even flatter.
- Material is pulled through the machine by drawing. This method is typically used for thin and/or long products.
- In forming, raw materials are shaped on a curved surface. Using it with your drawing, you can create cylindrical parts for your custom packaging.
- In coining, circular holes are made in the material by adding pressurized force. This creates a very intricate look in the Packaging.
- Using broaching, multiple rows of "teeth" are used to cut materials that would otherwise be impossible to cut with a steel die.
Many other types of die cutting are available in digital and offset printing, but this will give you an idea of the most common types.
There are also different types of die-cutting services. Flatbed die cutting press and custom dies are used in flatbed die cutting, also known as steel rule die cutting, including custom shapes. These can be used for thicker materials, larger packaging components, and short production runs.
Rotary die cutting uses cylinder-shaped dies to produce custom boxes or Packaging from flexible material for higher-volume production runs. This is an ideal solution for high-volume runs and designs that require exact accuracy.
Alternatively, digital die cutting eliminates the use of dies. Instead, lasers, blades, and tool bits score, crease, and cut the material. This type of die cutting is typically used for applications that require fast lead times but still require high precision.
Are Metal Dies Easy To Make?
It is possible to make your metal dies by welding different pieces together, but it is not recommended. It would help if you left the die cutting, shaping, and forming to the experts in printing and Packaging.
Let us design the metal die for your custom packaging to ensure it will work with our specialized machines.
Cutting Pads and Plates: What Are They?
The cutting plate or pad creates a "die-cut sandwich" of all the components and materials needed to design your Packaging. The sandwich includes the type of Packaging, the design, and more so that the final product looks exactly like you imagined.
The process is similar to putting a cookie cutter through the dough to create the desired shape, which can then be decorated. Die cutting is identical to cutting by hand, using cutting pads or plates. These pads or plates can wear out over time and must be replaced.
Are you interested in learning more? Our comprehensive A-Z guide to packaging definitions will help you understand industry terminology as you create your custom boxes.
Creating Packaging with Die-Cutting and More
Die cutting is a very versatile way to cut, shape, and print packaging so that the results can be repeated repeatedly without errors. In addition to being precise, die-cutting gives you great flexibility regarding retail Packaging.
It is understandable, however, that only some have expertise in Packaging and printing. At Luxury Custom Boxes , we are. We will happily answer any questions about die cutting or how it will work with your product packaging vision.
Don't worry if you have an idea for your product packaging but are still trying to figure out how to make it a reality. Our phenomenal artists and engineers can transform your vision for carton boxes, corrugated boxes, or other branded Packaging into a stunning, eye-catching reality.
Contact us for a free quote about our Packaging, printing processes, and design options to Decide how to proceed with your unique design. Luxury Custom Boxes can bring your product to life like never before.
