What is die cutting and how does it work?
What is Die Cutting? Die cutting is a manufacturing process where a die is customized through cutting, forming or shearing to craft a desired shape, design or pattern. Die cut printing is used in the packaging process to correctly cut, ship and print according to specific measurement specifications, as outlined in a dieline. What is a Die?
What is a die cut plate?
Cutting plates, also known as cutting pads, create a sort of “die cut sandwich” of all of the components and materials needed to make your packaging design happen. The “sandwich” is the type of packaging, the design and more so that the end result comes out looking exactly the way you envisioned.
What are the different types of die cut materials?
Examples of materials which can be die cut are paper, fabric, rubber, fiberglass, metal sheets, and plastic. Die cutting started in the mid-19th century to modernize the shoemaking industry.
How do you cut paper with a die?
Then, a die in the shape you would like cut is laid on top of the piece of paper. When the die is positioned where you would like the cut to be made, a (usually clear) mat is placed on top of the paper and die, to keep them in place and act as a “sandwich.” Once everything is in place, the lever is cranked,...
What is the purpose of die cutting?
Die-cutting is a process whereby a die is used to cut through materials such as paper and card on a die press. The process allows you to make an identical cut into material numerous times. For each job, a die, which is a shaped blade, is custom made for the item being created.
What is die paper?
Die cut shapes are the pieces of paper, cork board, fabric, or any other material that has been cut out by a die into a shape. Sometimes, people also refer to die cut shapes as paper embellishments, cut outs, and ephemera.
Why is it called a die cut?
It wasn't until the 1800s that the mass-production of items of a similar size and shape took off, and this old term “die” was used to specify that it was “created by machines”. Cut refers to creating a custom shape, and die cutting means the casting and cutting of shapes.
What is a die cut process?
What is the die cut definition? Die cutting is a fabrication process that uses specialized machines and tools to convert stock material by cutting, forming, and shearing. In printing, die cuts are used to create custom shapes and designs for labels. It starts with a part called, unsurprisingly, a die.
What are the advantages of die cutting?
Pros of Die-CuttingA die cutting machine can fashion shapes with a single punch so that identical forms can be made very quickly – even a manual die cutter makes shapes more quickly than any alternative method.You can achieve pretty complex shapes, with multiple cuts and multiple layers.More items...•
How do you die cut without a machine?
2:1912:55How To Cut Dies WITHOUT using a Die Cutting Machine - YouTubeYouTubeStart of suggested clipEnd of suggested clipOkay. You can do it a little bit with pressure. And just one time and you will see how it cuts. YouMoreOkay. You can do it a little bit with pressure. And just one time and you will see how it cuts. You don't need to pass like three four times can you see then you can continue.
How do you print a die cut?
0:562:17Die Cutting in Printing - YouTubeYouTubeStart of suggested clipEnd of suggested clipBuild a chase around it. The paper is then fed down into the cylinder of the cylinder rolls theMoreBuild a chase around it. The paper is then fed down into the cylinder of the cylinder rolls the sheet around and the bed basically moves in and out.
What is a die cut finish?
Hence, die cut printing refers to the process of using a die to cut through materials, such as paper and label stock, on a die press to create custom shapes and designs.
What is die material?
Dental die materials are used to create dental models featuring dies of the preparations for restorative cases. These materials can be gypsums or silicones or other types of materials that can be poured into a dental impression to solidify into a die model.
What are dies made of?
The die's cutting and forming sections typically are made from special types of hardenable steel called tool steel. Dies also can contain cutting and forming sections made from carbide or various other hard, wear-resistant materials.
How does a die work?
A die is a pre-shaped tool that works in conjunction with a press to manipulate the material into the desired size and shape. The press forces the material — plastic, metal or composites — into the die's cavity, thus creating a new object in the same size and shape as the die.
What is die in dentistry?
A die has been defined as the positive reproduction of the form of a prepared tooth in any suitable material. A cast is defined as a life size likeness of some desired form. It is formed within or is a material poured into a matrix or impression of the desired form.
What Are Dies?
Dies are metal shapes, words, or alphabet letters that can be used to cut images from a material. They’re made of metal and come in all kinds of fu...
What is Die Cutting?
Die cutting is a process in which you use a machine to mass-produce cut-out shapes, kind of like a giant cookie cutter. The coolest part is it can...
Which Materials Can Be Used in a Die Cutting Machine?
Be sure to use only thin materials like paper, fabric, or foam sheets in your die cutting machine. The last thing you want to do is to break someth...
What Are the Different Things a Die Cutter Can Do?
Die cutters can do so much more than simply cut shapes from a material. The best machines will also be able to crease, perforate, blank, emboss, an...
What is the History of Die Cutting?
Die cutting was first invented to help streamline the process of shoemaking in the mid-19th century. The soles could be cut out with dies, which he...
What Can Die Cutting Be Used to Make?
Die cutting can be used to make a wide variety of useful items from the clothes you wear to the décor you use for parties. The full list includes:S...
What is die cutting?
Die cutting is a broad term, but in crafting, the act of die cutting refers to a process in which you use a machine to mass-produce cut-out shapes. You can create the same shape, with the exact same dimensions, over and over without using scissors, stencils, or a craft knife. It saves time and makes your cut-out shapes look professional and consistent every time.
What is a die cutting machine?
Die cutting machines or card making machines are machines that cut shapes out of paper, chipboard (like cardboard but thicker and more dense), fabric and other materials. Most people who die cut regularly have personal die cutting machines that are about the size of a small toaster oven. These machines can sit on top of your crafting table or work space or can be stored in a small area and brought out when needed. There are even tiny tabletop versions like the Sidekick or Mini Evolution, and compact folding versions like the Sizzix Big Shot Foldaway.
What is a die?
In die cutting, dies are metal-shaped objects with a raised, sharp area for cutting. They are similar in appearance and effect to cookie cutters - the shape of the die is the shape that will get cut out on your paper.
Who invented die cutting?
Die cutting was invented in the mid-1800s in order to help streamline the shoemaking industry. Since cutting the soles of shoes was formerly done by hand, typically out of leather, the process was time-consuming, laborious, and expensive. The invention of the die cutting machine revolutionized work for cobblers and made shoes much more consistent as shapes were always cut the same size, the same way, instead of by hand. This meant that shoes could now be given standard sizing.
How does die cutting work?
For manual die cutting machines, a piece of paper is placed on the platform of the machine. Then, a die in the shape you would like cut is laid on top of the piece of paper. When the die is positioned where you would like the cut to be made, a plastic mat is placed on top of the paper and die to keep them in place and act as a “sandwich.”
How much does die cutting cost?
Die cutting is an initial investment. Think of it like sewing. Up front, there are a few costs for the necessities to get going, but once you have the essentials purchased, the following costs are all additions like trendy dies from new collections, papers, and other materials to cut, as needed.
What are die cut shapes?
Die cut shapes are the pieces of paper, cork board, fabric, or any other material that has been cut out by a die into a shape. Sometimes, people also refer to die cut shapes as paper embellishments, cut outs, and ephemera.
What is a die in printing?
In the world of printing, a Die refers to a thin, razor-sharp steel blade that has been formed into a specific shape or pattern (sort of like a heavy-duty cookie-cutter).
What is a die used for?
A die can be used to shape the entire perimeter of a printed piece, or it can be used to just shape one corner or an edge. A die can also cut out a shape or shapes from within the center of a piece. In addition to cutting all the way through a printed piece, a die can be designed so that it cuts a perforated outline of a shape.
Why do envelopes have die cuts?
A mailing envelope often has a die-cut window so that an address or information printed on its contents remains visible once the envelope is sealed. Even the simple business card slits or tabs found in some brochures and pocket folders are created with a die-cutting operation.
What is Die Cutting?
Die cutting is a process in which you use a machine to mass-produce cut-out shapes, kind of like a giant cookie cutter. The coolest part is it can be done in a factory or right at home.
Why was die cutting invented?
Die cutting was first invented to help streamline the process of shoemaking in the mid-19th century. The soles could be cut out with dies, which helped save time, money, and effort. This also meant that the footwear could be given standard sizes for the first time, which was completely revolutionary!
What Are the Different Things a Die Cutter Can Do?
Die cutters can do so much more than simply cut shapes from a material. The best machines will also be able to crease, perforate, blank, emboss, and add engravings.
What materials can you use in a die cutting machine?
Be sure to use only thin materials like paper, fabric, or foam sheets in your die cutting machine. The last thing you want to do is to break something because you tried to cut the wrong item. Here’s a full list of materials you can use in a die cutting machine: Paper. Adhesives.
Why are die cutters less effective?
Your die cutter will be less effective if your blades are dull. Be sure to spot-check the dies and change them out if they’re no longer sharp.
What is a manual die cutter?
A manual die cutter comes equipped with an easy cranking lever that activates steel dies that cut the material. These machines are typically smaller in size, which makes them the perfect fit for your craft table at home.
What is a die set?
The die set comes in the same shape, but includes a variety of sizes. Think of it like a nesting doll, where each die inside is slightly smaller than the last.
What is die cutting?
Die cutting is a process by which thin materials are cut to shape with the implementation of a die. Interestingly enough, die cutting is not limited to paper crafting. In fact, it is used widely in the manufacturing world to cut elements such as sheet metal, rubber, plastic, cloth, and many other substances for mass production. This process is even used to cut the template shape for cardboard boxes as well as around the paper shipping label so that items can be shipped all around the world. It is clear that many of the items we take for granted in our everyday lives include some kind of dies in their production.
When was die cutting invented?
The manual process yielded many inconsistencies between the shoes, hence the introduction of die cutting. Since then, cobblers were able to “create sole patterns that could be reliably replicated through the die cutting process.” With the advent of the mallet handle die cutting machine came the mass production of soles and standardized sizes for the masses.#N#It wasn’t until the early 1900s when further innovations in dies and die cutting machines were invented. The creation of the swing-arm clicker press helped the shoemaking industry and other industries to die cut different shapes and sizes with various sized and shaped dies. This then started the mass production of products like plastic, metal, tubing, and food items.#N#The 1950s saw the invention of hand-held die cutting tools and small table machines, which were mostly used for homes and schools. What started as a simple and convenient way to help cobblers speed up the shoemaking process has turned into a staple tool in every crafter’s home.
How to make an embossed impression on cardstock?
Simply place your cardstock on top of the embossing mat then place the die into position on the cardstock then run through your die cutting machine to create an embossed impression.
What was the invention of die cutting tools in the 1950s?
The 1950s saw the invention of hand-held die cutting tools and small table machines, which were mostly used for homes and schools. What started as a simple and convenient way to help cobblers speed up the shoemaking process has turned into a staple tool in every crafter’s home.
Why use coordinating die cutting?
Coordinated die cutting is especially useful for crafters who suffer from arthritis or other disabilities, as it is often less stressful on the hand to use dies than to use scissors.
What is a delicate word die?
Delicate Word Dies - These can be used as sentiments on cards or titles for scrapbook layouts. Whether it is the word “hello”, “thanks”, or “love”, a delicate word die provides a beautiful touch to any handmade project.
What are the two main categories of die cutting machines?
For at home or personal use, die cutting machines fall into two main categories: manual and digital.
What is die cutting?
Die cutting is the mass fabrication of cut-out shapes by shearing a stock material such as paper and chipboard using tooling called a die. A die is a specialized tool used in manufacturing to cut or shape a material fitted into a press. It has sharp edges used to pierce the material; it contains the custom two-dimensional shape of the finished part. The die cutting process works in the same principle as the cookie cutter where the dough is cut into smaller sizes. Examples of materials which can be die cut are paper, fabric, rubber, fiberglass, metal sheets, and plastic.
When was die cutting invented?
Die cutting started in the mid-19th century to modernize the shoemaking industry. Before die cutting was invented, manual labor was utilized to outline and cut the soles of the shoes by hands. This process required more time and manpower while the rate of production was low. The invention of die cutting resolved these problems in the industry. Patterns were made allowing shoemakers to replicate and standardize the sizes of the soles. Through years of discovery, die cutting had extended to revolutionize other industries and it is still evolving to cater to increasing demand and in making more complex designs. Today, this method is widely used in the manufacturing sector such as packaging, consumer goods, and automotive industries. Applications of die cutting can even be found in our homes and offices.
What is a flatbed die cutter?
Flatbed, rotary, and semi-rotary die cutters are considered industrial-scale die cutting machines, designed for thicker and more rigid substrates able to produce parts at a fast turn around. Meanwhile, manual and digital die cutting equipment are utilized to create simple and accessory parts. Its production rate is relatively slower and therefore suitable for low volume orders.
What is flexible die?
Flexible rotary dies are made of thin sheets of steel with engraved patterns, which contain the edges for cutting, wrapped around a base magnetic cylinder. These dies are suitable for low pressure and shallow or partial cutting. The cutting thin sheet can be replaced depending on the part to be cut. The magnetic cylinder can be configured for many flexible dies.
How does a manual die cutter work?
Manual die cutters work by pushing the crank lever which forces the steel dies to the substrate, hence cutting out the finished part. Soft materials like paper are best for this type.
What is a cutting assembly?
The cutting assembly is composed of a die board and a lower counter plate. The die board is the flat and rigid upper plate which contains a series of knives used to cut the stock material into finished parts.
How does a die board work?
To complete the cutting assembly, a lower counter plate is placed wherein the stock material is mounted and supported during the cutting process. The cutting head initiates a downward stroke to apply pressure perpendicular to the plane of the material’s surface. This pressure compresses the material, causing the edges of the die to penetrate against it. The die board comes in different configurations, depending on the cutting and punching steps involved:
What is die cutting?
Die-cutting is a popular manufacturing process in the packaging industry. Chances are if you’re not a packaging expert, you probably don’t have a good idea of what the die-cutting process actually is. Don’t worry, you’re not the only one!
Why do companies use die cutting?
Die-cutting is used by businesses to create unique custom packaging tailored to their brand narratives and customer experience. It is a very valuable process as it is easier, faster and more cost effective to produce custom packaging in larger quantities, making it a win-win situation for both manufacturers and businesses.
What is a Die?
To understand the die-cutting process, it’s important to understand the components used to carry out manufacturing.
Why die cut packaging?
The die-cutting process makes custom packaging more accessible for both manufacturers and businesses. While the set up costs can be quite expensive, this disadvantage is counter acted by never having to pay that fee again for your specific design.
Why is laser cutting important?
Since the introduction of laser cutters in the process of die-cutting, it has allowed for greater accuracy and precision when preparing die boards.
How many dies do you need to make a box?
You only really need 1 die to create thousands of boxes.
What is drawing in packaging?
Drawing: Pulls the material to a predetermined length. It is used to create lean and long packaging.
What is die cutting?
Die-cutting is a process used in many different industries to cut a thin flat material (in our case, paper) into a specific shape using a steel cutting die. It can be used to punch out a decorative shape or pattern to incorporate within a larger piece, or it can be used to create the main shape of an object by cutting the entire sheet ...
What type of die do you use for letterpress printing?
Instead of a type-high printing plate we use a type high wood mounted steel cutting die . The shape of the cutting die is often something we’ve designed and ordered from our local die-makers. Instead of tympan paper and packing (used to control the impression when printing), we use a sheet of metal on the press bed giving the die a hard surface to cut against.
Does paper affect die cutting?
Paper can affect the outcome – this is something to consider when choosing your paper or choosing to use a die-cut element. In our experience, thinner paper has less resistance and seems to cut more cleanly while thicker stock can yield mushy edges. Cotton paper can leave a ragged edge.
Can you die cut a pattern?
Complicated shapes or patterns may not work (ask your printer or die-maker). There is a minimum size for die-cut elements. The maximum size of the die-cut will depend on the capability of the press you are using.
Do you remove rubber rollers from a letterpress press?
The first few steps are essentially the same as letterpress printing, although since we’re not using ink we’re always sure to remove the rollers from the press before we start. We don’t want the dies to damage our rubber rollers!
What is die cutting?
Die cutting is a process by which a die (made out of sharpened steel) is used to cut irregular shapes out of printed sheets. Die Scoring is the process of pressing a crease into a sheet of paper to allow it to fold accurately. Scoring serves two purposes; it prevents the ink (and paper) from cracking at the edge of the fold and ensures ...
Why is die cutting so expensive?
Die cutting can become a wasteful and expensive process if a finished piece is not designed and planned properly. Structural designers work hand-in-hand with the die cutting and folding/gluing departments. Why? A well-designed structure is one that performs its function and can be manufactured cost-effectively for maximum production efficiency. This includes the process of sheet optimization. Sheet optimization is the process of designing products that can be nested on the press form (press sheet) for maximum use of the material. Nesting allows the die cutting layouts to fit tightly on the press form. This can simplify the die production, reduce material consumption and improve production efficiency. The image at the left shows how a food sleeve is nested on the press form. Notice the efficient use of paper and minimal waste that will result?
Why do we use rubber strips on dies?
Rubber strips are affixed to the die to help improve the cutting performance. The formal term for this part is “ejection rubber” and it is a critical part of the die cutting process. Ejection rubber is used on the dies to hold the sheet stable when the knives perform a cut.
How do substrates affect knife blades?
Substrates affect knife blade life. Just like your kitchen knife, die cutting knives get dull through extended use. Some have asked how many die cut impressions can be performed before the die cut knives need to be replaced. The answer depends upon the substrate that is being cut.
What is a Nick in a die cutting machine?
Nicks are the result of several small gaps we make in the die cutting knives. These gaps keep the die cut piece and the support material as one piece for final delivery to the pile. These gaps can also be inserted by the press operator using a hand-held rotary cutting tool.
Why do we use scoring in dies?
Scoring serves two purposes; it prevents the ink (and paper) from cracking at the edge of the fold and ensures the best quality product when folding paper or board stocks. When a die is made, the knives are placed in cutting positions and the scoring rules are placed in the scoring areas. The electronic die template is color coded to communicate ...
What is grain direction?
Grain direction is one of the most overlooked details when planning a successful print or packaging project. Paper grain is the direction the paper fiber runs on a stock, resulting from the paper manufacturing process. Paper is identified as either grain short (grain is parallel to paper’s short side) or grain long (grain is parallel to the paper’s long side), depending on how the paper is cut. Tear a piece of paper and you will see the direct impact of grain direction. Tearing against the grain will cause a jagged tear where tearing with the grain will allow for a straight tear. Paper folding is impacted in a similar manner. If a fold must go against the grain, the piece will need to be scored. This makes for a smooth fold and minimizes the chances of inks and coatings cracking. When designing your printed piece or packaging, close attention must be paid to the paper grain direction. In packaging, producing a larger sized folding carton with the wrong grain direction can cause many problems including a distortion called “box bulge”. Some paperboard mills manufacture bi-directional stocks which minimize cracking and make for easier production. Contact us for a list of these versatile stocks.
History of Die-Cutting
What Is Die Cutting?
- Die cutting is a process by which thin materials are cut to shape with the implementation of a die. Interestingly enough, die cuttingis not limited to paper crafting. In fact, it is used widely in the manufacturing world to cut elements such as sheet metal, rubber, plastic, cloth, and many other substances for mass production. This process is even ...
Manual Die Cutting
- For manual die cutting, steel rule dies used to be the most common. This kind of die includes a sturdy base, typically made of wood, and a shaped line of steel embedded within a layer of foam rubber. The rubber helps to eject the cut material from the die itself. Although durable, steel rule dies are thick and cumbersome and do not lend themselves well to the home crafter. Because o…
Die Cutter
- Dies are not all you need to get beautiful perfect cut-outs for your paper crafting projects. You also need a specially designed die cutting machine to allow you to cut out your dies. However, there are many different die cutting machines and die cutting toolsto help you make the most of your die cutting experience. Die cutting machines are a staple in most paper crafters’ craft room…
Frequently Asked Questions
- Q1 - What are die cut stamps? WHAT ARE DIE CUT STAMPED IMAGES? A1 - This is where you stamp your chosen design and then cut it out using a matching die. This means your will not need to fussy cut the image, saving you time while crafting. Q2 - How do you make a die cut card? A2 - There are a few ways to do this, the easiest way is to use cover dies. With your card base open a…