Design context

Die cutting

Die cutting is a process that uses a steel die to cut away specified section of a design. It is mainly used for decorative purposes and to enhance the visual performance of a piece.


Die cutting is a common process used to cut a range of sheet materials, including paper, cardboard, rubber and plastic. Most standard cardboard boxes or packages are made using this relatively straightforward technique. In addition to cutting out shapes, this method of cutting can be used to create creases, perforations and slits.
 The die is produced by a die or cutting-forme maker out of a flat base or substrate that is usually made out of high-density plywood. The die maker uses a band saw or laser cutter to cut precisely positioned slits into the wood. The die maker then cuts and bends a steel rule, essentially an elongated razor blade made out of hardened steel, and positions it into the slits in the substrate to form the cutting edge. Finally, rubber pads, known as ejection rubber, are adhered to the substrate to help eject the material after it has been cut. The wood, steel rule and ejection rubber combine together to create what is commonly referred to as a cutting forme. Once the die maker has completed the cutting forme, it is immediately ready for production. The die is attached to the top surface or platen of a die cutting press, which will provide the force required for the job. The material to be cut is positioned below the die and then the press is put into action. If registration is an issue, the material is positioned against a stop or in a locating nest. The cutting edges of the steel rule penetrate through the material until they come into contact with the bottom platen; then the press reverses and the cut part is exposed. In some applications, a softer material is placed below the material to accept the cutting surfaces of the steel rule.