Diecuts

Die-cuts are shapes produced by cutting materials with a die—a custom tool that contains the outline of the desired shape. The term is commonly used in printing, packaging, and crafts to describe cut-out forms or the overall process of producing them. Die-cuts can be made from paper, cardboard, vinyl, fabric, leather, foam, and thin metals, depending on the die and press used.

Industrial methods: Die-cutting is performed in presses and can be divided into flatbed and rotary processes. Flatbed die-cutting uses a stationary cutting die mounted in a press and a counter-press platen; the material is moved and pressed to cut shapes, sometimes with scoring or crease lines for folding. Rotary die-cutting uses a cylindrical die on a roller that cuts continuously from a web or sheet, suitable for high-speed production.

Types of cuts: Through-cut, which cuts completely through the material; kiss-cut, which cuts through top layers but leaves backing intact; perforations or partial cuts to enable tearing. Some dies create creases or scoring along with cuts to facilitate folding.

Applications: Die-cutting is used to produce labels, packaging blanks, greeting cards, business cards, stickers, and other consumer products. In textiles and leather, die-cutting shapes patterns or forms. In crafts and hobby markets, digital or plotter-based die-cutting machines enable short runs without traditional dies.

Tooling and economics: Setting up a die requires a custom tool, which can be expensive, making die-cutting most cost-effective for larger runs. Short runs or highly variable shapes are increasingly served by digital die-cutting methods with computer control, lasers, or scoring knives.