What is Die Cut and How is it Used for Packaging?

The die cut is commonly used in the packaging industry for various reasons. One important reason is to build a unique brand identity through the customized die cutting on the packaging boxes. If you want to know what is cutting die in detail, this blog will help you.

But before moving to the process of die cutting, let’s have a look at what is a die and why it is important in the packaging industry. 

What is a Die?

A die is a piece of metal with raised edges pressed on the desired material to get that shape. It is like a cookie cutter and can have customized shapes for your desired packaging designs. 

It is also known as cut and die because the die cuts through material to get the desired result. A die can be anything; words, numbers, phrases, and even symbols, as per your packaging and design needs. 

Why is die-cutting Used in the Packaging Industry?

Now that you know what are die cuts, the next important thing is to know its application in the packaging industry. Die cutting is used to get the exact shape of every single packaging box. There are multiple reasons why packaging industries use die-cutting for their boxes. 

Most brands want to understand what is die cutting in printing, before using that process on their packaging boxes. Die cut packaging helps in ensuring that your packaging has a uniform look, which cannot be achieved when done manually. 

Moreover, it also helps in producing large quantities for better efficiency. You can get customized die-cutting plates to create a unique brand identity and it can grab customer’s attention. 

Different Techniques of Die Cutting

Several packaging industries use different techniques for die-cutting according to their needs. The two most common techniques used in the packaging industry are:

Flatbed Die Cutting

Flatbed die cutting is used in industrial high-volume production. Flatbed uses the hydraulic principle and uses a steel rule die to press on the material to get the die cuts. 

This technique provides less residual as it cuts close. The dies used in the flatbed technique are affordable thus it is not an expensive technique. However, it needs longer setup times which reduces the efficiency. 

Rotatory Die Cutting

The rotatory die cut technique is also used for industrial purposes and is more advanced than the flatbed technique. It is electrically operated and uses cylindrical dies. 

Rotary die cutting provides better precision than flatbed and needs little setup time for better efficiency. However, the setup cost is expensive and the dies need high maintenance. 

Types Of Die-Cutting Plates

Die-cutting plates are used to protect the material when it is passed from the machine. It is part of the die-cut sandwich that comprises these plates, the die, and the material. 

These plates act as the surface on which the machines press down. They are used to ensure that the pressure is even on all sides for better results. They are primary tools for die cutting and are changed repeatedly. 

There are different types of die cutting plates. Some of them are:

Clear Cutting Plates

Made up of polycarbonate plastics, the clear-cutting die plates are the ones that come in direct contact with the machine. In other words, these are the bread for your sandwich. 

Metal Cutting Plates

Metal-cutting plates are used for intricate designs and better precision. They  provide a finer cut than the polycarbonate plastic. Knowing how to use metal die cuts involves understanding complex designs.

Plastic Shims

Plastic shims are used for additional protection. They are not the alternative of the cutting plates but they ensure more safety when added to the layers.

Magnetic Shims

Magnetic shims are added for the same reason however the only difference is the magnetic principle. The magnetic shims keep the dies in place as they are rolled. 

How to make die cut work smoothly? The answer lies in using high-quality dies and maintaining them. It is important to get the right size of plates and shims for better results. Moreover, changing them after regular intervals also ensures better results. 

What Materials Can Be Die Cut?

Diecut does not act on paper alone. There are many types of die cut materials that you can use such for your customized packaging boxes such as: 

Paper

Paper is the most common material for die-cutting. This type of material is easiest to use in manual machines. 

Foam

When foam is added under the thin paperboard, it gives a raised effect and a better outlook. 

Vinyl

Vinyl is another type of material you can use if you want to get water-resistant stickers for your packaging. 

Thin fabric

If you need thin fabric die cuts for your packaging designs, the automatic die cuts will provide you with those. 

Final Words

Customized shape die cutter can help your brand in creating a unique brand identity. But these custom shapes mostly have hidden charges. However, with Custom Lane Boxes, you are free of the hidden charges. Moreover, you get free delivery all over the US. 

Get a quote from us today!