What Is Die Cutting and Why Is It Important

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what is die cutting

Die-cutting is a common process in packaging and printing. Using a metal die, we cut, crease, or emboss cardboard or other materials into specific shapes. Die-cutting allows you to create packaging boxes, labels, or displays that meet your exacting specifications. Die-cutting can create shapes that are impossible with standard cutting machines.

From simple squares to complex hollow designs, die-cutting not only adds a touch of design to your product but also enhances the user experience.

Last updated: August 2025 | Estimated reading time: 8 minutes

what is die cutting
what is die cutting

This article will answer your questions

  • What is die cutting?
  • What is a die-cutting machine?
  • What are the common die-cutting processes?
  • How does a die-cutting machine work?
  • Why is die-cutting important in packaging and printing?
  • How does die-cutting impact branding and product presentation?
  • Can die cutting handle complex shapes and special designs?
  • What does excellent die-cutting look like?
  • How to solve the problem when die cutting is inaccurate?
  • How much does die cutting cost?

What is die cutting?

Die-cutting is the process of cutting, scoring, or embossing paper or sheet material using a metal die. It’s commonly used for products like packaging, labels, and stickers, creating uniform and precise shapes. However, it’s not limited to paper products.

From folding cartons to stickers, die-cutting determines the final form of packaging. It enables the creation of effects like windows, rounded corners, handles, and custom-shaped logos. For this reason, die-cutting and printing are crucial steps in many packaging designs.

die cut design samples
die cut design samples

Common uses of die cutting

  • Folding boxes for cosmetics and electronic products
  • Display box with transparent window
  • Special-shaped stickers and labels
  • Display stands and promotional items
Use Case Common Die-Cut Material Benefit to You
Folding cartons Window, tabs, creasing Paperboard Better fit; easier assembly
Labels and stickers Custom shapes Self-adhesive label stock Stronger brand recognition
Display stands Irregular/complex cuts Corrugated cardboard Stand out on shelf

What is a die-cutting machine?

The die-cutting machine is an important piece of equipment used in packaging post-printing processing. The accuracy depends not only on the machine’s tonnage and speed, but also on the paper feed settings and die set-up.

For example, the front baffle should be kept at 1.5 times the thickness of the paperboard, and the side baffles should be kept at 1/2 of the paper width, otherwise it is easy to “run the plate” or “shift”. This is the main reason for many inaccuracies.

Working principle of die-cutting machine

  1. Paper feed into the machine
  2. The die is pressed onto the paper to cut or crease
  3. Create cuts, creases, or dashed lines
  4. Removal of waste
  5. Finished product collection and stacking

Tips: Die-cutting pressure should not be too high; generally, 60%–70% of the cutting depth is sufficient. Excessive pressure can damage the die and create burrs.

Why is die-cutting important in packaging and printing?

Die-cutting greatly improves the processing efficiency and product quality of packaging and printing. Without die-cutting, your box can only be square; with die-cutting, you can increase:

die cutting essentials for innovative packaging
die cutting essentials for innovative packaging
  • Fold lines for easy assembly
  • Open windows to display products
  • Special-shaped design makes the product stand out

It can effectively improve production efficiency and reduce labor costs; it can cut packaging materials into complex and diverse shapes to improve the appearance of packaging; it is also suitable for labels, stickers, and adhesives.

Can die cutting handle complex shapes?

Yes. Digital die-cutting technology can cut complex shapes, such as intricate angles, fine lines, and curves. It also features a high-precision cutter and motion control system to ensure smooth edges. Round die-cutting technology can handle even more complex shapes and sizes. However, accuracy depends on die settings, pressure adjustment, and waste removal processes.

Our experienced employees add indentation strips to the die to ensure the depth of the crease, and use moderate pressure to ensure a clean cut.

What does excellent die-cutting look like?

die cutting guide
die cutting guide
  • The cuts are clean and neat, ensuring no burrs, no tears, and clear lines
  • No deformation, will not cause the cardboard to curl, wrinkle or deform
  • Clear indentation, convenient for subsequent folding and forming
  • Waste is automatically removed and enters the next process smoothly

What to do when die cutting is inaccurate?

  1. Check the paper feed settings: Is the baffle adjusted correctly?
  2. Correction of die-cutting plates: ensure consistency in printing and die-cutting working environments, and reduce paper deformation
  3. Adjust the pressure to avoid damage to the die
  4. Choose the right paper material: avoid paper deformation or breakage

Case: A Shanghai factory experienced frequent shutdowns due to “plate runaway”. Later, by adjusting the sensor electric eyes to the four corners of the cardboard, the waste removal speed was increased, and production capacity increased by 20%.

How much does die cutting cost?

The cost of die cutting depends mainly on the complexity of the die, the material and the output:

  • Simple die (square box): $100–$200/set
  • Complex die cutting (with windows or special shapes): $300–$800/set
  • Large-volume production: The unit cost is extremely low, while small-volume production results in higher mold costs.

The latest trends in die cutting in 2025

Digital die-cutting: no physical die required, suitable for proofing and small batch packaging orders.

Automated waste removal: reduces labor and improves production efficiency.

Environmentally friendly materials: More customers are asking for recyclable cardboard.

Market trends: By 2025, digital die-cutting in the packaging industry will grow at an average annual rate of 7%, mainly driven by e-commerce and short-order customization.

FAQs

Mainly used for folding boxes, labels, stickers, display stands, etc.

The die is pressed onto the paper to cut or crease, ensuring fast and consistent results.

The die cutting cost is a one-time cost, and the unit cost is very low when producing in large quantities.

Conclusion

  • Die-cutting is a key process to achieve customized packaging shapes.
  • Accuracy depends on paper feed setting, die installation and pressure adjustment.
  • Excellent die-cutting can enhance brand awareness, save transportation space and improve efficiency.
  • Avoid common pitfalls: excessive pressure and inadequate waste removal.

Next step: If you want custom packaging, ask the supplier to provide die-cut samples first to ensure the design is feasible before entering mass production.

About XiangGe Package

We are a professional packaging manufacturer with over 10 years of experience in die-cutting, printing, and carton design. We export to over 100 countries, serving the cosmetics, electronics, and food industries. Our strengths lie in our high-precision die-cutting and strict quality control.

Contact us today for a free consultation or samples.

Last updated: August 2025

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