Understanding the Die-cutting Process in Custom Packaging

The die-cutting process is a popular manufacturing technique in the packaging industry. It involves the use of dies used to cut soft materials into various packaging designs and shapes.

The ability to produce custom packaging in volume is where the true value of the die-cutting process lies. Die-cut packaging is easier, faster and more cost effective, allowing for the creation of custom packaging on a larger scale. 

In this article, we'll explore the die-cutting process and its role in custom packaging. 

You will also see. 

● Die-cut boxes explained in detail

● How cutting dies are made

●Die-cutting technology 

● The FEFCO corrugated packaging category 

● Finishing options that complement die-cut box design

Understanding the die-cutting process

A cutting die is essentially a giant cookie cutter that is pressed into the material to form the desired shape of the package.

Die cutting has come a long way from its origins in the shoe industry during the industrial revolution. 

Originally designed to aid in the mass production of packaging, die cutting has evolved into a versatile manufacturing process.

Almost any shape, design or pattern can be created using cutting dies.

Customized packaging is produced using custom steel dies and die-cutting machines. 

This form of manufacturing allows for mass production of packaging. But more importantly, die-cut packaging ensures precision accuracy. 

How are cutting dies made?

The development of cutting die technology and manufacturing techniques ensures the most efficient and accurate die-cut box design. Typically, the package outline is generated by Computer-Aided Design (CAD).

This digital drawing is transferred to a piece of hardwood called a template. 

The most sophisticated method of drawing the design on the template is to burn it on the wood surface using a state-of-the-art laser cutter. 

The introduction of the laser in this process ensures greater accuracy in drawing on the moldboard. 

Cutting dies are made using metal strips called rule or steel rule. The cutting rule is shaped into shape using a rule bender, which bends, cuts and grooves the steel into the desired shape.