Die Cutting Machine

Die Cutting in Product Packaging- Complete Process and Current Trends

What is the process of die-cutting?

In recent times, each and every industry has faced immense competition, and it has become quite hard to sell products without earning customer interest. However, the design and artwork of any product covering make the final look of products appealing to the audience. And we all know that in today’s highly competitive market, packaging design plays a pivotal role in attracting consumers and leaving a lasting impression. 

Moreover, die-cutting is considered a versatile and creative technique that allows brands to craft out-of-the-ordinary packaging. Such packaging helps their product to stand out on the shelves. On the other hand, product packaging plays a pivotal role in catching the consumer’s eye and conveying vital information about a product. Among the numerous techniques used in packaging, die cutting stands out as a versatile and innovative process. 

Understand the process of die-cutting of packaging boxes

In the die-cutting process, manufacturers use to create precise and custom shapes on various materials like:

  • Paper
  • Cardboard
  • Metal

With the help of different dies of different sizes and shapes. After the die lines are created on the required material, the cut-and-die process starts. It involves using a die, which is a specialized tool or template, to cut or shape material into a specific design or pattern. In this way, brands can freely create any pattern and design on their product boxes. 

Role of die cutting in product packaging design

With the changing trends in the packaging industry, customer tastes and preferences of the customers also innovated. And the latest design trends keep top positions in gaining customer attention. However, die-cutting is also one of the top-rated design trends for product boxes as well as bags. Different brands used to die-cut their product boxes with their required or brand-specific symbols. This would endow a unique touch and elegance to the final look of the products. 

As we all know, in today’s highly competitive marketplace, capturing the consumer’s attention is a paramount goal for brands. Product packaging serves as the first point of contact between a brand and its potential customers. So, to make a memorable and lasting impression, many brands are turning to innovative packaging design. The die-cutting option is a versatile and creative technique that plays a significant role in making packaging designs viral. However, it often contributes to the creation of viral packaging designs. 

Step-by-step process of die-cutting

We all know well that die-cutting is a complete process that involves several steps. The brands need to know about the complete process of die-cutting before ordering their boxes from any custom packaging manufacturer. It is also an understood fact that the packaging design needs of every brand vary. Some brands need to use their symbol in die-cut shapes, and some need to add a unique shaping dimension. So, here is the step-by-step process:

Die Cutting-processing

1. Create the design first

Without design, it is next to impossible for the custom packaging manufacturer to create a die. So, the brands need to clearly communicate their required design to their packaging manufacturer for the die-cutting. 

2. Creation of die

Once the designers know about the die-cutting design, they prepare the dies accordingly. However, it totally depends on designers to create the dies with the help of manual and digital die-cutting machines. 

3. Select the material 

The selection of material is also an important step because the material that needs to be cut is laid out flat and may be secured in place. Whether you need to cut the cardboard sheets or plastic, you need the flat sheets of that material. 

4. Print the Dieline

When the material is set accurately, then the designers print the Dielines on their material to ensure the areas of cutting. And if you want to know what a die line is, then the answer is the lines from where we cut the design with the help of dies are known as Dielines. 

5. Placement of die

In order to reduce the errors you need to place the die at the right position and it is also one of the most crucial steps in die cutting. However, it would also reduce the chance of errors so you need to carefully do this step. 

6. Pressing of die

Now, you are required to press the dies on the material. For this purpose, you need a press or machine. With this machine, you can apply pressure on any material and cut your desired shape on it. 

Removal of cut areas

The last step is the removal of cutting areas. It is required to cut the extra areas of material from cuttings to provide a complete and finished look. 

So, this is an easy process in which you can create your die-cutting design on the packaging solutions. However, creating the die-cutting process is a little costly, but it helps in the escalation of the sales of any specific product. The reason is the adorable outlook that is granted to the product packaging by die-cutting. 

Historical background of die-cutting designs

The die-cutting process has its roots in ancient times, as we all see that many historical civilizations used to cut materials like leather and textiles with the help of sharp tools. However, with the passage of time, this cutting technique also gets advanced. The Industrial Revolution also provided a number of the latest ways of cutting efficiently and accurately.  

Current trends in die-cutting and different available options 

Here are a few amazing as well as trendy options that are available for the die-cutting of various materials. So, you can use any of the following options to create custom die-cutting patterns on your boxes and bags. 

Die cut Machine

Rotary die cutting: 

Another method that is extensively used in the industry is rotary die cutting. In this method, cylindrical dies are placed on the rotary press. This type of cutting is fruitful for huge and bulk cutting. 

Flatbed die cutting: 

Flatbed die cutting is also known as steel rule die cutting. This is one of the most common methods. However, it utilizes a flatbed press and a die made of steel rule blades. This method is versatile and suitable for various materials, which helps make it popular in the packaging industry.

Laser die cutting: 

If you want to provide great artwork in the form of intricate cutting patterns then the laser cut would be the most suitable option. This die cutting provides a net-like look by cutting a complete artwork of pattern form the material you need. 

Waterjet dies cutting: 

A type of die cutting that is used to cut materials by applying a high-pressure stream of water mixed with abrasive particles to cut materials. Such a type of cutting is suitable for soft materials like rubber. 

Few words in the end

So, the brands who need to go for the die-cutting design of their packaging are free to select any type of die-cut option. However, it is also advised to select a famous custom packaging manufacturer to avoid the chances of errors. So, you are advised to choose your Mr. Right for the creation of die-cut boxes for your products.