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What is the Die Cut Process in Packaging?

The packaging business uses die-cutting frequently as a manufacturing technique. If you are not an expert in packaging, you likely have little understanding of the die-cutting procedure.

You're not the only one, so don't worry!

Die-cutting originated with letterpress printing and developed into a more specialized manufacturing process. In the packaging industry, die-cutting involves using a tool to cut materials into various patterns, shapes, and styles.

It is mostly employed in the production of folding carton packaging, although there are other uses.

Businesses utilize custom die cut packaging that is best for their brand storytelling and customer experience. Since it is simpler, quicker, and more affordable to build custom packaging in larger quantities, it is a valuable procedure that benefits both manufacturers and enterprises.

Everything you need to know about the die-cutting procedure will be covered in this article. 

What is a Die Cut Packaging?

die cut box

Understanding the production components is essential to knowing the die cut packaging process thoroughly.  

What precisely is a "die," then? 

A die is a unique instrument used with a press to cut and shape packaging materials. A die can be compared to a "mold" designed to cut out your unique packaging boxes.  

Formation of die is ultimately the first step in producing your unique packaging. Before being mounted on a press, a custom die is formed utilizing tools and die makers. 

To begin die-cutting your first batch of customized packaging, you should finish the dieline by this time. 

Read More: Digitally Printed Die-Cut Boxes Are The Perfect Tool To Promote Your Brand

Can a Die be Used More than Once? 

Actually, it is advised to do so! 

It is expensive to create dies for every packaging design. But since it only needs to be paid once, the benefits much outweigh the disadvantages in the long run. Once a die is developed, it may be used again on the press to produce large quantities of packaging, making it much more affordable for your company. 

Consider a scenario in which you have three products, each of which comes in the same basic packaging but with distinctive artwork for product uniqueness. 

All you need is one die to make thousands of boxes. 

Die-cutting is a very efficient method for producing distinctive custom die cut packaging that eventually becomes a pillar of your brand story. 

Knowing the Die-Cutting Procedure 

Imagine a die-cutter as a large cookie cutter pressed into the material you want to use to make your customized packaging boxes. 

Die cut boxes can now be designed more precisely and efficiently because of the advancements in technology and manufacturing methods.  

Computer Aided Design (CAD) is typically used to produce packaging outlining, which enables the transfer of digital dieline drawings onto the wooden die board. 

To create more exact outlines, the dieline is often burned into the surface of the die board using laser cutters. For this reason, before beginning the die-cutting process, make sure the cut lines, fold lines, bleed lines, and safe zones are accurately marked out over your dieline. 

Manufacturers now prepare die boards more accurately and precisely because of the introduction of laser cutters into the die-cutting process. This technique is very helpful in the manufacturing of die cut cardboard packaging. Moreover, to ensure minimal movement and precise placement during cutting for greater precision, die boards are positioned beneath the material during the die-cutting process.  

When the blade has cut through the material, the die boards nearly serve as a framework to maintain straight and precise cuts. 

Read More: Kraft Paper: The 101 Guide

Uses of Die Cutting Process

die cutting process and uses

Die-cutting has a variety of uses despite its name, including: 

Perforating: creates a succession of tiny cuts that make it simple to tear 

Through Cutting: removes material completely. 

Scoring: leaves a mark, indent, or partial cut on a specific area. 

Creasing: This process generates a fold line for easy building. 

Each of these functions has a specific purpose for various packaging materials and structural designs. 

Creasing is particularly helpful when making corrugated packaging

Various die cut foam packaging inserts and rubber bits are hammered into the die board together with steel rules to guarantee that the die filters the corrugated board during production. In order to facilitate folding, this ensures the crease lines are distinct and leave a lasting imprint. 

The die-cutting machine firmly presses the die into the material to cut out the shape and carry out the preprogrammed functions. These functions are mirrored on the die and die board.  

Afterward, the surplus material is gathered and reused if possible!

Read More: Small Business Packaging Ideas To Stand Out From The Competition 

Die Cut Methods

die cut box packaging

When studying the die-cutting procedure, we discussed a variety of uses, but it also employs various techniques to build a die cut paper packaging box. These techniques allow for a truly personalized packaging experience and open up a whole new universe of structural design options. 

There are many different kinds of die-cutting techniques, such as; 

Blanking: A precise flatness measurement is made via blanking. Flat material is clipped from its outer edge and then cut.  

Drawing: involves pulling a substance to a particular length. It is applied to produce long, slim packaging.

Forming: Using a curved surface, form the raw material. Normally, it is combined with a drawing to create rounded cylindrical shapes.

Coining: Making circular holes in materials using pressured force to generate minute and complex structural design features are known as coining.

Broaching: Broaching is a process that employs several long rows of cutting teeth to cut materials that are typically too thick or hard to cut in other ways. 

The die-cutting process can be used on any packaging material, as evidenced by the list above! 

The Finishing Touches 

As was already stated, businesses can have genuinely personalized die cut packaging boxes because of the die-cutting technique. 

We all know that luxury packaging conveys a high-end, sophisticated vibe yet is expensive to make. 

However, if you have the resources, think about employing the die-cutting technique to create personalized premium packaging as it is cost-effective. 

Many finishing techniques that highlight and enhance your die-cut design are available when using the die-cutting process. 

A few of these are:  

Custom packaging is easier to access for both manufacturers and businesses because of the die-cutting technique. Even though the setup fees can be rather high, you'll never have to pay them again for your particular design; thus, this drawback is balanced. 

Read More: The Ultimate Cheat Sheet on Cardboard Packaging

This method efficiently produces huge quantities of die cut packaging orders with high-quality design accuracy. 

custom boxes

Additionally, it provides such a wide variety of options, features and techniques that distinguish between custom and stock packaging and enables companies to be quite creative with their product packaging boxes