diecut

Die-cutting is a manufacturing process that uses a die to cut shapes from sheet materials. The die is a tool with blades or punches arranged in the shape to be produced, mounted in a press. When material passes between the die and a counter die, the shape is cut and separated. Die cuts can be through the material, or the cut can be limited to the top layer while leaving the backing intact, depending on the intended use.

Die-cutting setups vary by method. Flatbed die-cutting uses a stationary bed and a moving ram to cut rigid or semi-rigid sheets. Rotary die-cutting uses a rotating cylinder to cut continuously from web stock, ideal for high-speed production of labels, stickers, and cards. Dies come in configurations such as steel-rule dies and solid steel dies, with carbide options available for longer life on thick or tough materials. The process can be configured for through-cut or kiss-cut operations (where the material is cut but the backing remains intact).

Common applications include packaging (boxes and inserts), labels and decals, greeting cards, scrapbooking, leather and fabric components, vinyl graphics, and promotional or decorative items. Die-cutting enables precise, repeatable shapes with clean edges and is well suited for high-volume runs.

Advantages and limitations: the method offers fast, repeatable cutting and tight tolerances, but requires a nontrivial upfront investment in dies, making it most economical for medium to large production quantities. It is less cost-effective for very small runs or rapid, one-off prototyping. Die-cutting is widely used in printing, packaging, and various craft and industrial industries.