Die cutting is a common process used widely all across the packaging sector. If you are an expert, you will have a good understanding of this process.
However, for beginners we are here to describe everything, starting from its history to how it works and what are considerations for it. Also, we will elaborate on its role in creating perfect custom packaging solutions easily.
What is Die Cutting?
Die cutting has grown to be immensely popular over the past few decades. The main reason for its popularity is its usefulness. It is a process that uses a special machine and a die to cut out multiple shapes from different materials.
To understand it better, let’s consider a cookie cutter and the way it shapes the dough according to your desire. The same is the case with a die cutting machine. However, the material in this case can be paperboard, cardboard, corrugated board, rigid board, plastic, and even metal.
What is a Die?
A die is a specific type of tool designed from sharp steel to create a desired pattern. As the die is pressed onto the material, it cuts it into the required shape. There are multiple types of machine die cutting. Their use depends upon the type of materials and their production requirement.
The Evolution of Die Cutting: A Brief History
It was first brought into practice by show making industry during the first Industrial Revolution. Before introducing this process, the shoe manufacturers have to first outline and then cut the shoe sole with their hands. It was extremely time-consuming, required much effort and human resources, and had a minimum production rate. Die cutting emerged to be a good answer to all these concerns.
Over time, it made its way into several other industries owing to continuous improvement. At present, it is making a big contribution to the packaging sector as well. Finally, it is possible to create intricate designs in a short time.
Die Cutting Machines
A die cut machine usually comes in two forms.
- Flatbed Die Cutting
A flatbed die cut functions by pushing the die with pressure onto the material from the top. It works similar to a stamp. This type is usually suitable for less complicated designs and thicker materials.
- Rotatory Die Cutting
In this process, the die covers a cylindrical anvil. The materials of packaging boxes are passed through the machine and are cut into the desired shape. This method is comparatively fast and good for high-volume runs with elaborative designs. Gemini die cutting machine is a good example of it to create indicate patterns.
Manual vs Digital Die Cutting Machines
Die cutting machines can be both, manual and digital. In the case of manual, the machine uses a turned crank. The pressure is applied to leverage the shape through the tool’s rollers. The setup may have motors to facilitate applying pressure.
However, a digital die cut is managed through software. It eliminates the need for a steel die as the blade cuts the desired shape. The process is employed using a computer, cell phone, or even a customized cartridge.
Die Cut Stickers & Labels
A die cut sticker machine is a popular choice to create stickers and labels in any shape and size ranging from simple to complex. It’s a good way to brand and advertise your products.
Die Cut for Folding Cartons
Die paper cutting machines can produce folding cartons that are a very useful product all across the packaging sector. Die cut process can create cartons in unique shapes other than rectangular, even with windows and special closures.
How Die Cutting Works?
Die cutting delivers an amazing personalized packaging experience directing you to a wide range of structural design choices. Let’s have a look at how it works:
- Blanking: It is all about taking an accurate flatness measurement.
- Drawing: The material is pulled to a desired length.
- Forming: The curved surface shapes the raw material.
- Coining: With pressure, circular holes are made into the material.
- Broaching: By using large rows of cutting teeth, hard or thick material is cut.
Role of Die Cutting in Custom Packaging
Die cutting has always been on the top to create the best custom packaging solutions. Here is its role in this regard:
- Premium Branding
With it, you can create unique packaging shapes and styles to create a better shelf impact and uplift branding.
- Functionality
Folding die cut cartons offer features like convenient-to-open tabs, seals, and locks to make your packaging more functional.
- Efficiency
It allows your packaging to be designed optimally, making the best use of storage space and space on the carrier, reducing costs significantly.
- Consistency
A die cut ensures that everything is identical. It is good for branding and assembling. In this way, businesses can ensure that all of their packaging products are identical reducing worry and enhancing satisfaction.
- Speed
The process leads to efficient production runs as the die cutting tool operates very fast. It leads to a speedy delivery of bulk orders in a minimal time frame.
- Versatility
Die cutting is versatile as it applies to a wide range of materials to ensure meeting different packaging needs.
Get Lucrative Finishes with Die Cutting
Undoubtedly, the phenomenon of die-cutting creates a customized experience and enhances the usability for every business. The process is quite affordable however adding luxurious finishes might prove a little expensive. For example, a die cutting embossing machine creates a look like nothing else. Its appeal is matchless so it’s worthwhile making such an investment. Here are some of the best finishes for die-cutting:
Wrapping Up
Die-cut packaging allows businesses to personalize their packaging as per their desire. This makes them incorporate various designs and prints that impact the customers’ buying decisions. However, if you are looking for one of the best packaging suppliers near me, the name Unique Custom Packaging is at the top. We use advanced and premium quality instruments for die cutting to deliver accuracy and excellence. Just explore our amazing design choices and see how our experts surpass your expectations.
