diecutting

Diecutting is a manufacturing process that uses a shaped cutting tool, or die, to cut materials into specific patterns. In paper and packaging, the die is pressed through the substrate, producing one or more shapes in a single stroke. Cuts can be through the material (through-cut) or non-penetrating (kiss-cut) when only the top layer is severed.

Two common forms are flatbed die-cutting and rotary die-cutting. Flatbed die-cutting uses a stationary die and a high-pressure press to cut sheets, offering accuracy and suitability for thick materials. Rotary die-cutting uses a cylinder-mounted die on a rotating press for high-speed production with web materials such as labels and laminates. Dies may be steel-rule, solid, or flexible assemblies. Digital and laser-assisted systems enable short runs and rapid prototyping, but may trade precision or throughput for speed.

Materials include paper, cardboard, film, foil, fabric, and laminates. Die-cut shapes are widely used in packaging, greeting cards, labels, stickers, tags, and decorations, as well as in textiles and automotive interiors where precise shapes are required.

Origins date back to the 19th century with the growth of the printing industry. Today die-cutting is a standard method for mass production due to repeatability, clean edges, and efficiency, though initial tooling costs and setup time can be a consideration for small runs. Waste generated in the cutting process is managed through design optimization and material choice.