Understanding the Die-Cutting Process

Think of a die-cutter as a giant cookie cutter that is pressed into your desired material to create your custom packaging.

Developments in technology and manufacturing techniques in the die-cutting process has allowed for more effective and accurate designs of die-cut boxes.

A packaging outline is generally created by Computer-Aided Design (CAD) and allows for digitized drawings of your dieline to be transferred onto the die board which is made from wood.

Your dieline is typically burned into the die board’s surface using laser cutters for more precise outlines.

This is why making sure you get the cut lines, fold lines, bleed lines and safe zones properly mapped out on your die line before moving forward with the die-cutting process.

Dieline for die cutting

Since the introduction of laser cutters in the process of die-cutting, it has allowed for greater accuracy and precision when preparing die boards.

Die boards sit underneath the material during the die cutting process to ensure minimal movement and accurate placement while cutting for more precision.

Die boards almost act as a guideline for the blade once it’s made a cut through the material keeping the cuts straight and accurate.

While cutting is in the name of this process, die-cutting has many different functions including;

  • Through cutting – cuts right through the material
  • Scoring – leaves an impression, indent or partial cut on a specified area
  • Creasing – creates a fold line for convenient construction
  • Perforating – leaves a series of small cuts for easy tearing

Each of these functions serves a purpose for different types of packaging materials and structural designs.

Creasing is especially useful for the construction of corrugated packaging.

Steel rules are hammered into the die board accompanied with an array of foam and rubber pieces to ensure the die bounces off the corrugated board during production.

This ensures the crease lines are prominent and leave a lasting impression for easy folding.

As for the die-cutting process itself, the die-cutting machine firmly presses the die into the material to cut out the shape and perform it’s programmed functions mirrored on the die and die board.