What Is Die Cutting?
Die-cutting is the process of cutting printed board or paper into a precise custom shape using a die, a block fitted with sharp steel rules. The same die also creases fold lines, so a flat sheet can be cut and scored in one pass into a carton, mailer, label, or window shape.
In more detail
A die-cut works like an industrial cookie cutter. A custom die is built with sharp steel "cutting rules" bent to the outline of the shape, plus blunt "creasing rules" that press fold lines without cutting through. The printed sheet is pressed against the die, and in one stroke it is cut to shape and scored ready to fold.
This is what makes non-rectangular and engineered packaging possible: self-locking e-commerce mailers, cartons with tuck-in flaps, hang-tag shapes, display standees, and windows cut into a carton front. Anything that isn't a plain square is almost certainly die-cut.
Because the die is bespoke to each design, there is a one-time tooling cost to make it, after which every sheet cuts identically. For very short runs or prototypes, digital cutting (no physical die) is an alternative.
Key points
- A custom die cuts the outline and creases the fold lines together
- Enables mailers, tuck cartons, tags, windows, and display shapes
- One-time tooling cost, then identical repeatable cuts
- Digital cutting is an option for short runs and prototypes
Common questions
What is a die in die-cutting?
A die is a custom-made block fitted with sharp steel cutting rules shaped to your design's outline, plus blunt creasing rules for the fold lines. It's built once per design and then cuts and scores every sheet identically.
Do I pay extra for die-cutting?
There's a one-time tooling charge to make the die for a new shape, after which the per-unit cost is low. For repeat orders the die is reused. For very short runs, digital cutting avoids the tooling cost but has a higher per-piece cost.
Related terms
Where it's used
Written by LeRoy Print Packs, a printing and packaging manufacturer making cartons, corrugated boxes and labels in-house. Get a quote