Apr. 21, 2025
The capabilities of die cutting are vast and include a variety of commercial, industrial and consumer-grade goods. Its versatility makes it suitable for various projects, but die cutting is more effective for some needs than others. Recognizing when to choose this manufacturing method and understanding its limitations will increase the chances of getting the results you want. Discover everything you need to know about this process in our guide to die cutting below.
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Die cutting cuts pre-determined forms into thin material, such as rubber, foam, plastic, wood, metal and fabric. The process can take several forms. Common die cutting methods include using a laser, implementing a rotary tool or creating a custom die for punching out forms.
Die cutting has existed for almost 200 years. Not long after the Industrial Revolution, die cutting used a punch to press holes into leather manually. This form of cutting initially helped shoemakers produce shoes more uniformly and at a faster pace by creating precisely cut pieces of leather. Over time, die cutting evolved to become more automated and cut into different types of materials. Today, many industries, from electronics to medical products, take advantage of the customizable forms die cutting can create in large quantities.
The die cutting process depends on the type of equipment used, but it involves choosing the material and selecting the right equipment for the job. For methods that don’t use lasers or a rotary tool for cutting, you may need to create a die.
The three main methods for die cutting include steel rule, rotary and laser. Each process has separate pros and cons, and the same die cutting method may not work for every project. The methods for die cutting include:
The type of die cutting method that works best for you depends on your project requirements. For mass production, a steel rule cutting with a customized die is best. If you already have dies, you can use this method for whatever project the shape of the die accommodates. For heavier materials, the steel rule cutting method works well because the bed supports the weight of what you’re cutting.
Rotary cutting makes objects like gaskets easily. It can cut materials like fabric, plastic and sheet metal and offers a quick turnaround for high-volume projects.
Laser cutting is a method that professional die cutting businesses use. This type of cutting works best for high-precision work required by electronics and similar industries. Beginners don’t often use this method because of the equipment involved.
Die cutting has countless uses. For example, die cutting with a rotary cutter often crafts gaskets out of elastomers or rubbers. Laser cutting can help create electrical insulation to meet the high standards of military equipment. Customized packing inserts made from die-cut foam offer specific forms cut into material to safely cradle the packed products.
As a beginner, you may want to start with paper, fabric or leather die cutting. These materials are easier to cut through. For beginners, crafting projects such as gift cards, holiday decorations, scrapbooking materials, labels and gift tags are ideal places to begin.
For die cutting, the materials used depend on the type of machine you’re working with. For most beginners, a steel rule on a piece of flat material will suffice. Make sure the die will cut through what you want to work with. The amount of pressure used will determine whether the die goes through the piece or creates an imprint, scoring into the material without cutting through it.
A cutting pad under the material can protect the surface underneath, whether it is the die cutting flatbed or another surface.
Paper, fabrics, leather, wood, metal, plastic and foam are commonly used with die cutting. Find these materials for die cutting and others from hobby stores, craft shops or online.
When die cutting initially, avoid using extra-thick materials that would require too much pressure from a die. You also cannot use materials too thick to pass through the machine.
One of the most common mistakes with die cutting is the die failing to cut all the way through the material. This error can happen if the die does not have enough pressure behind it or if the material is too thick to cut. Try sending the material through the machine a second time or adding a piece of cardstock or bulking material under the project to bring it closer to the die and increase pressure. If these options fail, consider replacing the die — it may have a defect.
Depending on your experience with die cutting and what you’re trying to achieve, you may find potential pros and cons to the process. Understanding those advantages and disadvantages can help you make the right considerations for your project.
Die cutting provides multiple advantages for projects that require it, including:
Die cutting is great for thin materials, but it does not work for all projects. For instance, thick materials or different ones at the same time in the cutter may not work.
Additionally, not using a die cutter properly could result in scoring the material instead of cutting through it. Trying to fix this error by running the project through the machine again could fix it. But if the material shifted between the first and second passes, the second cut may not align with the first, creating a misshapen cutout.
The steel rule dies and rotary cutters are also very sharp. Mishandling of them could result in physical injury. And if you need highly precise cutting, you’ll likely not have access to the laser die cutting machines required.
Professional die cutters with more precise machinery can overcome these disadvantages. Experts know how to control the die cutter’s pressure based on the material to ensure proper cutting. Plus, they can use laser cutting for accurate die-cutting results.
Don’t risk making a mistake on die cutting projects that require extra skills to achieve. Instead, request professional die cutting to have a quality job done. Die cutting services from a professional company with the right materials and equipment can help you complete your projects.
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Industrial die cutters are widely used in manufacturing, specifically in the packaging process. But these machines have grown more advanced over the years. Today, industries ranging from automobile and medical device manufacturing utilize die cutters in their operations as well.
For instance, a team from MIT has discovered how to mass produce disposable face shields using die cutting for COVID-19-related use.
One of the biggest advantages of using die cutting machines, therefore, is that they have a wide range of applications. Manufacturers use them for processing cardboard and carton, foam, paper, plastic, rubber, and fabrics, all while ensuring the uniformity of each die-cut piece.
If you’re considering purchasing a die cutting machine, make sure to invest in the right kind. Multiple kinds of die cutters are available today, from manual to digital variations. Each has its benefits and drawbacks that affect your production efficiency.
A flatbed die cutter uses custom steel rule dies that match the shape and design you want to produce. Hydraulic pressure pushes the die downward to punch out parts from the stock material.
The vertical motion can cause a slight curl on the edges of the finished products. But you can avoid this by determining the ideal thickness or amount of the stock material and learning the right mitigating techniques.
Flatbed die cutters can process materials either in roll or sheet form.
Rotary die cutters are electrically operated, using rotating cylindrical dies called die stations. You feed the material into the die station, which holds a rotary tool that cuts out the parts from the sheet or roll.
The die stations are available in solid and flexible varieties. The choice depends on the material you’re using, the specifications you’re trying to meet, and the project’s lead time.
Depending on its specs, rotary die cutting machines can perform multiple functions in one processing cycle, including layering and laminating materials.
Digital die cutters or desktop cutting machines don’t have dies. Instead, they use lasers, blades, and tool bits controlled by computers to execute the designs. You can create designs from scratch using a software then export them to the machine for processing.
This die cutting method is popular among facilities with steep requirements for lead time and volume. You don’t have to create new dies for each project, so you can quickly jump from one task to another.
The question of which die cutting machine to acquire depends on your operational needs. Die cutters, particularly the more advanced ones, can perform various functions, but not every machine will have all the capabilities at the same time. Consider your production needs to determine which ones you want to prioritize for your die cutting machine.
Below are some of the common functions of die cutters:
This is the basic capability of die cutters, which is to cut through all the layers and completely separate the design from the stock material.
Kiss cutting is exclusive to adhesive-lined materials. The machine will cut through the top layers – the face and the adhesive – and leave the backing layer intact. The die-cut part won’t be separated from the stock material, but you easily detach it from the backing layer. Kiss cutting is popularly used for labels and stickers.
Perforating means punching in a series of holes onto the design. The design isn’t fully separated from the stock, but the holes make it easily detachable. Some designs include perforations that aren’t intended for easy removal, such as adhesive bandages.
Scoring leaves a die indent or partial cut at a single stress point. It only cuts through half of the material, reducing the thickness to allow for profile folds.
Similar to scoring, creasing creates a fold line on the stock material. The difference is that creasing produces an inward bulge between two stress points. This indent helps the material hold its shape after you fold it.
Utilize your die cutting machine to its fullest potential by choosing one that meets your production needs. Consider factors like machine size, ease of use, the materials you normally use, and your volume and speed requirements.
Provide ample training for your staff to make sure they know how to operate, troubleshoot, and maintain the machine. This way, you can avoid downtimes and keep your operations running for maximum productivity.
If you’re still unsure of which die cutting machine to get, SBL Machinery can help you make the right choice. We carry a range of state-of-the-art die cutters and other packaging equipment. Just tell our experts what you’re looking for in a die cutter and we’ll point you to a model that satisfies your requirements.
The company is the world’s best China Cardboard Die Cutting Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
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