What is the Die Cutting Process in Packaging?

Die-cutting equipment is a commonly used machine in the manufacturing industry. It helps create packaging die and replicate the impact multiple times at an extremely low cost.

When you are new to the industry and just exploring methods for affordable or cost-effective packaging, you may not know about this feasible method. For this reason, we have explored how you can use die-cutting equipment, how it is possible to use a range of designs and shapes, and what is the process of making die packaging.

What is Die?

Die-cutting equipment is a machine that is used to create a die, which is a type of mold. A die is a metal piece cut into a required shape, which helps cut paperboard when we are making customized packaging for products. Since you can shape and form a die in a desirable manner, you have great customization flexibility. You can creatively carve out the required packaging material in the desired number from just one die.

To create this die, we require die makers and tools. Once the die is prepared it can be used in die-cutting equipment to create packaging.

What is the Die Cutting Process?

The die-cutting equipment is like a cookie-cutter. When we press the cookie cutter in the spread dough, we get custom designs and shapes. A piece of die-cutting equipment is also similar to this, it helps you create customized packaging, designs, and shapes.

The following steps are used to create a die and packaging with the help of this die:

1. Firstly, we create a design for our packaging with the help of a CAD (Computer-Aided Design) tool. With the help of these digitized patterns, we can transfer them to the wood die board.
2. The die line created with the CAD tool is burnt into the surface of the die board with the help of a laser cutter. This gives us precise and accurate lines. Since we are using laser cutting, you need to ensure that the fold lines, cut lines, bleeds, and safe zones are correctly mapped on the drawing board. The laser cutter will give us clean accurate cuts every single time.
3. Usually, the die board is placed under the material, which helps reduce movement and receive an accurate placement.
4. When you are cutting the die, there are different types of processes:
   1. The through cutting process cuts the materials directly.
   2. The scoring process creates an impression or partial cut on the area.
   3. The creasing method makes a fold to ensure simple construction.
   4. The perforating process creates various small cuts so that you can tear them away.
5. For different patterns of packaging, you can use the relevant die-cutting process. For example, in the case of corrugated packaging, you can use the creasing die-cutting process.
6. Once the die is prepared, we use the die-cutting equipment to press the cut out in the desired material to create the packaging shape from it.
7. The remaining material is sent for recycling.

How Many Times You Can Use One Die?

It is possible to use one die multiple times. In fact, experts recommend using one die over and over again. The die is created with a reusable material with the purpose of making packaging simpler. If you were to make a different die for every packaging, then that would cost your business a lot of money.

In a business where you need to create volumes of packaging, using the same die helps you optimize your packaging budget greatly.

For example, you are selling three types of bakery products to customers. The artwork and design on the packaging are different for every product, but the shape is the same.

You can create one die for every product and make your packaging hassle. We can directly print the artwork on the material without changing the die.

Methods Used For Die Cutting

There are several types of methods used for the die-cutting process. For different uses, you may consider a varied method. Check the following die cutting methods:

• In the blanking process, we slice flat material by chipping the exteriors. With the help of this method, you get the right flatness in the die.
• The drawing material pulls your material to create the required length. When you want long or lean packaging, this method is feasible.
• The forming process curves the surface as required for the packaging. We usually use both forming and drawing together to make cylindrical shapes and curved edges.
• The coining method helps cut circular holes with the help of pressure. You can use this technique for intricate and meticulous structural designs.
• The broaching process is used when you have a hard material or thick sheet. You need many rows of the relevant cutting teeth to create a shape.

Conclusion

From the above discussion, it is obvious that we can create a die for different types of shapes and designs. Further, we can use different die-cutting equipment or process to cut through any type of material. Simply evaluate your requirements and find the correct die-cutting process for your packaging type.