Die Cutting

What is Die Cutting?

Die cutting is a manufacturing process used to generate large numbers of the same shape from a material such as wood, plastic, metal, or fabric.After the cutting is complete, pressure is applied by the use of hydraulic or mechanical presses. Die cutting sometimes goes by the names dinking or blanking.There are a few types of die cutting but the most well known are rotary die cutting (also known as gasket die cutting) and flatbed die cutting.Rotary die cutting is often done inline with printing. The primary difference between rotary die cutting and flatbed die cutting is that the flatbed is not as fast but the tools are cheaper. This process lends itself to smaller production runs where it is not as easy to absorb the added cost of a rotary die.
Chain-Rotary-Die Cutting- Machine

Types of Die Cutting

  • Blanking Die
Blanking die cuts are made in one step and produce a flat shape. This is the type of die cutting most often encountered in standard paper die cutting
  • Bending Die
A bending die bends a flat material into the necessary shape by pressing the material over a specially shaped die.
  • Forming Die
Forming dies curve a blank by bending it along a curved surface.
  • Bulging Die
A bulging die literally "bulges" the closed end of a tube, either with a rubber part or with use of oil or water, depending on the type of die.
  • Shaving Die and Trimming Die
A shaving die shaves off the sides of a shape until it reaches desired accuracy, while a trimming die cuts off irregular parts of a blank.
  • Coining Die
Coining dies form blanks that have different sides, as with a standard coin.

Small Die Cutting Machine

What is the purpose of Die Cutting?

The purpose of die cutting is to mass-produce shapes made from paper, metal and fabrics. There are many different kinds of products that require the use of a die cutting machine. Stickers, labels, boxes, posters, paper letters, paper decorations, and many more objects require the die cutting process. Each die cutting tool has a slightly different purpose. Large die cutting machines are designed to produce many cuts of the same design very quickly. Hand die cutters are designed to make small batches of die cuts for numerous purposes. 

What is the process of Die Cutting?

The die cut shapes are sometimes called “blanks,” because they are usually finished and decorated before being sold. The process is widely used on an assortment of materials all over the world, and many manufactured products contain several die cut components, often assembled together in aseries of steps to create a finished product.One of the most popular uses for die cutting today is with at home scrapbooking.
There are three major steps in the Die Cutting process:
1.The Set-UpThe first step in the process is to bend the blade into the shape to be cut (called the die), and to mount it to a strong backing.

2. The Material
The material that blanks will be cut from is placed on a flat surface which is also supported by a strong backing. The machine the die is attached to then presses the die downward into the material to cut it. Often there are several layers of the material so that many blanks are cut out at once.

3. Finishing TouchesOnce all of the blanks are cut, they're taken elsewhere to be finished in their own way. If the blanks were to be used in making wooden chairs for instance, then different blanks might be stained or painted and sent off to a variety of locations to be used in other parts of the manufacturing process.

Computerized Die Cutting Machine:

There are a number of different computerized cutting machines available on the market some of them allow you use your computer to cut any font or shape that you have on your hard drive, but others are designated for industries such as (computerized die cutting press
and feeding systems ( USA CP-150). This machine is used in different industries:


  1. Automotive
  2. Clothing
  3. Computers
  4. Footwear
  5. Home furnishing
  6. Medical
  7. Toys games and Sports

There are many advantages for using computerized die cutting machine:

  1. Working capacity of 15,000 to 20,000 cuts per 8 hours.
  2. User friendly computer control.
  3. 50 cutting program memory for different die shapes. Cutting program shown on dialog type computer monitor.
  4. Program and cutting die change within 5 minutes or less.
  5. Optional auto nesting software is available to achieve best material yield through computer auto nesting.
  6. Combine with optional feeding system to obtain automated die cutting systems for high production even with many daily die changes.
  7. Material savings up to 20% and more.
  8. Save material,reduce labor.
  9. Increase productivity, extend Die-Life, assure cutting quality.

Who uses Die Cutting?

  • Major Companies mass producing paper for newspapers/magazines or books,and they need large quantities of paper cut the same.
  • Car companies use die cutting machines for cutting different car parts in large quantities, so vehicle on the assembly lines are all the same.

  • Many clothing companies use die cutting machines as well, an example would be a machine to cut soles for shoes, or the cardboard in baseball hats.
  • You might have used a die cutting machine and not even known it, a hole punch is a very small die cutting machine.
Large Die Cutting Machine

What are the advantages and disadvantages of Die Cutting?

1. Uniformity
Die cutting creates multiple identical forms, based on the shape of the dies. Uniformity is important for most mass production applications, including cutting out cardboard box forms, cutting plastics for forming toys and electronics, and creating vinyl lettering.
2. Speed
Industrial die cutting machines may cut dozens of identical shapes simultaneously, and sheet metal or plastic can be fed through the machine in quick succession, making production especially fast.
3. Low Cost
Die cutting can be less expensive because only one tool or machine is needed to create the shapes. With intricate die-cutting, making pieces is much more
efficient, saving labor time.

4. Less Waste
Die cutting leaves less waste material around the shapes than other cutting methods, because the dies can be lined up very closely. Reducing waste also saves money and is better for the environment.

1. Lots of moving parts
Higher risk for injury.
2. Specially trained operators
Only a handful of people have the knowledge and training needed to operate these machines.

Different kind of die cutting tools



  1. http://www.youtube.com/watch?v=Jqhb3GjbSO4
  2. http://www.ehow.com/list_7641007_advantages-die-cutting.html
  3. http://www.wisegeek.com/what-is-die-cutting.htm
  4. http://www.thomasnet.com/about/die-cutting-22510804.html
  5. http://en.wikipedia.org/wiki/Die_cutting_(web)
  6. http://www.ehow.com/facts_5003368_types-die-cutting.html
  7. http://digitalprintingtips.com/printing-tips/t-30-552/applying-diecuts.asp!
  8. http://apmcards.com/index.php