Die-cutting uses a custom-shaped steel blade to cut paper, card or board into shapes that cannot be achieved with a straight guillotine trim. It produces clean, repeatable shapes at speed and suits medium to long production runs. We produce die-cutting in-house at our Marrickville production facility.
What is die-cutting
A die is a wooden or metal base with a shaped steel blade set into it. The die is mounted on a press, and the printed sheet is fed through. The blade cuts the sheet to the specified shape in a single press stroke.
The same die can include cut lines, crease lines and perforation lines. This means a single pass can cut a folder shape, score the fold lines and perforate a tear-off section simultaneously.
When to use die-cutting
Die-cutting is the standard method for any printed product that is not a rectangle. Common applications include presentation folders, pocket folders, packaging nets, business cards with shaped edges, swing tags, table talkers, shelf wobblers and POS displays.
The die is a one-off cost. Once made, it can be reused across multiple print runs. This makes die-cutting cost-effective for repeat jobs and medium to long runs where the tooling cost is amortised across enough units.
For short runs or one-off prototypes where die cost is not justifiable, our Zund digital cutting table cuts the same shapes from a vector file without tooling. For very intricate patterns, laser cutting achieves finer detail.
Design considerations
Die-cut artwork is supplied as a vector dieline, typically on a separate layer in the artwork file. The dieline shows the cut path, fold scores and any perforation lines. Bleed should extend at least 3mm beyond the cut line.
Minimum radius on inside corners is approximately 1mm. Sharp internal corners may tear rather than cut cleanly. Structural integrity of the finished piece should be considered, particularly on packaging nets where fold panels need enough material to function.
Digital cutting as an alternative
Our Zund cutting table uses a blade head guided by a digital file. It cuts, creases and perforates without a die. Setup time is minimal and there is no tooling cost.
Digital cutting is slower per unit than die-cutting on a press. It suits short runs, prototypes, sampling and jobs where the shape changes between versions. For production runs above approximately 200 to 300 units, a steel rule die becomes more efficient.
How we produce die-cut work
We commission dies from specialist die makers or produce simple dies in-house. The die is mounted on our press, registered to the printed sheet and tested. Production sheets are fed through and cut in a single pass. Waste is stripped and finished pieces are stacked and inspected.
For digital cutting, sheets are positioned on the Zund table and the blade follows the vector artwork. Both methods are completed on our production floor.
Need custom-shaped cards, folders or packaging? Get in touch to discuss die-cutting for your project.
Frequently Asked Questions
How much does a die cost?
Die costs depend on size and complexity. Simple shapes start from approximately $150. Large packaging dies with multiple fold and perforation lines cost more. The die is reusable.
Can I die-cut thick board?
Yes. Steel rule dies cut card and board up to approximately 2mm thick. Thicker materials may need our Zund table or laser cutter.
What is the difference between die-cutting and laser cutting?
Laser cutting uses a focused beam and has no tooling cost. Die-cutting uses a physical blade and requires a die. Die-cutting is faster for volume; laser cutting is better for fine detail and short runs.
Can I get a prototype before making the die?
Yes. We cut prototypes on our Zund digital cutter using the same artwork file. This confirms the shape and structure before you invest in a die.
How long does die manufacture take?
Typically 2 to 3 working days. We factor die lead time into the overall production schedule.