Die Cutting Explained

Die Cutting Explained

Die cutting is the process of cutting a label shape with a die. Most self-adhesive labels and some wet-glue and in-mold labels have to be die-cut to shape as part of their manufacturing and finishing process. Depending on the type of label and the printing and/or die-cutting requirement, the process may be performed using high or hollow dies, flat dies, rotary dies, or most commonly now digital die cutting.

What is a die?

A die is a tool or device used to cut a desired shape, form, or finish in any material; most commonly to produce a label or a specifically-sized sample. In the case of a self-adhesive label, the die is placed within the converting line or press and is used to only cut through the face materials of the pressure-sensitive laminate, but not the release liner. The matrix waste can then be removed to leave the desired label shape on the web. Dies may be constructed from flat steel strip cutting rules or as solid rotary tools or made as flexible dies for mounting on a magnetic cylinder.

Exploring Varieties of Die Cutting

High or Hollow Dies – these are used for cutting glue-applied labels to shape and are made of cold-rolled steel which is forged and welded to create the required shape and height. In use, the stack of labels is either stationary with the die moving or the die is stationary and the stack is pressed against it. In either case, sufficient space must be allowed between each label to ensure clean cutting. The sharpness of the die is critical, as are finished cut label tolerances.

Flat dies – these are most commonly produced by bending lengths of accurately fashioned steel rule which has been finished to a current bevel along one edge. To form a cutter, the rule, once bent to shape using a special bending tool is placed in a base into which the shape or shapes of the label(s) have been cut. In this way, the rule is supported during use on the press and retains a high degree of accuracy.

Rotary dies – these are engraved by electronic discharge from a cylinder of solid steel to leave the cutting edge standing proud around the cylinder circumference. An alternative method is to use thin steel plates that have the die configuration fixed over the surface. They are then mounted for use by wrapping the thin steel around a magnetic cylinder.

Digital die cutting – this has evolved from laser cutting technology used to cut out die base boards prior to inserting the rule. As with variable imaging or digital printing, the required shape and size of the label are programmed by a computer, with a laser beam and lens system used to cut out die baseboards prior to inserting the rule. Both paper and filmic labels can be cut using this method.

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