Packaging and Printing industries use the die cutting process to cut different materials like paperboard, chipboard, plastic, fibre or foil with the help of die in different shapes and sizes.
Die Cutting is highly important in precise cutting according to given dimensions without causing any error. For this purpose, die-cut printing is used, which gives the exact shapes every time for a sleek and professional look of the packaging boxes.
However, Premium Custom Boxes is among the best manufacturing companies with modern die cutting processes to provide the ideal boxes of various types and sizes. But still, if you are new to the industry or want to know about die cutting its types and processes in packaging and printing then continue to read on.
What is a Die in the Die Cutting process?
Die is specifically a tool that is used for the die cutting process. A die is a sharp tool consisting of sharp blades for cutting. For instance, you can imagine a cookie cutter that is designed to cut exactly according to the required shape and size. Likewise, the die also has various shapes to cut the material according to the size and dimension of the box.
So, in the die cutting process, the die cut is the key element that can provide you with the ideal boxes. To get the perfect packaging the different die designs include the following.
- Nesting Dies come in uniform designs for making layered die-cut backgrounds with borders. This is also used for creating designs for window boxes.
- Corner Dies are placed in the corner of the material used in making scrapbook borders with embossing and debossing techniques.
- Edge Dies are a bit similar to corner dies but they are used for making the edges of the material unique and fancy. You might have seen the gift boxes, their edges are crafted with edge dies.
However, talking about die cutting, just like the different types of dies, die cutting has different methods discussed below to give you a perfect custom packaging experience.
- Blanking is used to cut the material from the edges to produce an accurate degree of flatness.
- Drawing is used to get lean and long packaging.
- Forming is done to obtain the round or cylindrical shape of the material that is perfect for round-shaped luxury packaging boxes.
- Coining creates holes in the packaging material that can be used for various customized boxes.
- Broaching uses multiple cutting teeth to cut the hard material. This can be used on the material for the customization of rigid boxes.
Types Of Die Cutting Machines
Die Cutting machines can be manual, digital or industrial depending upon their uses. Here are the types of die cutting machines that can be used by packaging industries, fibre, or metal according to their materials.
- The Manual machine is operated by hand and uses a crank that is turned in to cut the material. This is used for small runs of packaging.
- The digital machine is controlled digitally. You can select the design shape and the blade inside the machine will cut the material and provide you with your required one.
However, the industrial machine is used for large-scale production of shapes and speeding up the cutting process. This is the most preferred machine for packaging custom boxes.
Types of Diecutters in Packaging Industry
Due to the huge variety of packaging material different types of cutters are used. Besides this, for the variety of packaging boxes the shapes and sizes are also different so to get the desired custom boxes, the following types of diecutting are used.
Rotary Diecutters
As indicated by the name these cutters are used to cut the material in cylindrical, tapered,semi-elliptical and spherical shapes. The cutter moves circularly and cuts material to the required shape. This is a perfect cutter to produce high volumes of packaging shapes.
Flatbed Die Cutters
These cutters use the hydraulic flatbed process to cut or perforate the material to get the desired shape. This is the best cutter to produce large-scale projects that need complex cutting. They are suitable for low volumes of consistent cuts. And is less expensive than rotary cutters.
Laser Die Cutters
It is one of the expensive cutting methods that use a laser through a computer guide, provides excellent designs and can deal with complicated shapes brilliantly. The laser cutter uses a high-speed laser to cut and force materials to specific shapes and sizes.
Digital Die Cutters
Digital cutters are used for creating designs that are needed in a short duration of time. For on-demand orders like business cards, folders, gift cards or table tents. However, this is a bit expensive as the cost per unit is high and is not suitable for long runs.
Steel Rule Die Cutters
The steel cutter is used to cut hard materials and press down the materials with sharp blades. This can be used on a variety of materials from foam, rubber, and paper to rigid or corrugated materials. This is used for medium runs and to obtain a broad variety of shapes.
Rotary Die Cutters With magnetic Cylinders
These cutters come with magnetic cylinders to give high-quality designs. They allow a faster die cutting process. These magnetic cylinders give precise cuts for continuous accuracy. It also helps in reducing costs by providing flexibility to improve the speed of your operations and the accuracy of your cuts.
Besides die cutting these magnetic cylinders can be used in various printings like UV printing or flexographic machines.
Punch Press Die Cutters
This is a traditional method used for the cutting of thin materials using a blade. However, mechanical pressure is applied to get the desired shapes. Punch press die cutting is highly suitable for medium to high volumes with high cutting force.
Kiss Cutters
This cutter is used to cut the top layer of the material leaving the liner, backing or remaining layers untouched. This is widely used for the production of custom stickers and labels.
Die Cutting Process For Custom Packaging
For die cutting, the primary step is to have an accurate dieline of your custom box. A dieline is essential in packaging as this outline is then transferred on the die board’s surface with laser cutters. The laser cutters burn the design on the hardwood with high accuracy and precision. During the die cutting process, the die board is placed under the material to ensure the slightest movement and accurate placement.
The die cutting machine firmly presses the die onto the material to cut out the exact shape. However, during the process die cutting involves the following functions to provide the ideal packaging shapes for customized boxes.
- Through Cutting: This cuts right through the packaging material
- Scoring: In this function, an imprint, indent or partial cut is made on a specific stress point.
- Creasing: It allows for the inward folding of the material by constructing two parallel lines.
- Perforating: This involves the process of marking holes in a line making it easier to tear.
Create Your Custom Packaging With Die Cutting!
You must have got an idea about diecutting and how it plays a pivotal role in the customization of various packaging boxes. From eco-friendly kraft, and corrugated to premium cardboard and rigid materials, die cutting is available for all materials to get the desired box dimension, shape and size. But we understand not everyone is professional enough to perform all these processes with high perfection.
So, Premium Custom Boxes are here to assist you. Our expert team can help you in making your ideal packaging boxes for your businesses if you are running a small business or large, our team will happily provide you with endless options from food boxes to custom boxes for every product you want. Contact us anytime, we provide non-stop customer service.
