Cutting techniques can make or break a project budget. That is why it is important to learn when to use the right machine for the job. Otherwise, you could be losing unnecessary money. We will look at what die cutting is and when you should use it!
In its simplest form, die cutting is essentially just a large cookie cutter for your design. It’s meant to pump out parts fast and precisely. Similar to screen printing, the setup for die-cutting takes longer but is faster on the production end. Its sweet spot is large quantities with substrates less than .5” thick. If you have a thicker substrate or smaller quantities that’s okay! There are plenty of other cutting options and we have even die-cut foam up to 3” thick! That is why it’s important to have a printer with the knowledge and alternate cutting capabilities in-house.
A die-cutting project has 3 elements.
1. The Die Line
The die line is essentially the guide for us to make the cuts or creases. These die lines can be very tricky to read, but it is imperative that they are correct.
2. The Cutting Die / The Die
A die can either be curved or flat. We typically used a curved die (aka a rotary die) when the parts are small and there is a dramatically higher volume (think sticker size). Every cutting die has a base with blades sticking out of it. Some of those blades are sharper to cut straight through and some are duller to score the material in case you need it to fold or bend. The rubber pieces are to help the blades cut evenly.
3. Die-Cutting Machine
There are 3 major die-cutting machines: roll fed die-cutting, sheet fed die-cutting, and rotary die-cutting. Typically, a die-cutting machine is 4 feet wide so you would want the dimensions of the die-cut part to be less than 22” x 32”. We don’t believe in being held back and that is why we have some of the largest format die-cutting machines in the US.
The more you are under budget, the more revenue you produce. It is important that you are using the most efficient method based on your project specs and not constrained by machine capabilities. Otherwise, it can limit your budget and weigh down your bottom line. Shameless plug: If you want to know if your project is as efficient as it could be, we would be happy to give you a 2nd opinion! Our scope of equipment ensures that you are using the best method for your project.