Secondary Research - Die Cutting

Die-cutting is a process used in many different industries to cut a thin flat material (in our case, paper) into a specific shape using a steel cutting die.  It can be used to punch out a decorative shape or pattern to incorporate within a larger piece, or it can be used to create the main shape of an object by cutting the entire sheet of paper in an distinct/designed way.  More simply put: for us it’s way of making a hole in paper in a desired shape using the same presses that we use for letterpress printing.

Like letterpress, a die-cut element draws attention to the 3D nature of paper and the character of the material itself.  We mostly use die-cutting as a feature – taking an industrial process and turning it into a design element.  As a letterpress print shop, here are some common ways we use die-cutting:

• to create die-cut windows for messages on greeting cards
• to create a unique shaped greeting card (examples include heart die-cuts, scallops, mini-paper sculptures)
• as a design element in one of our new wedding suites
• to create die-cut coasters, hang tags, and rounded corners on business cards for clients
• to make the boxes in which our cards are packaged.

Die cut involves cutting irregular shapes in paper or paperboard using a die. A die can be used in printing for cutting, scoring, stamping, embossing and debossing. Dies are normally custom pieces, but your printer will usually have some standard dies (such as for rounded corners) available if you don’t need a custom template; check with your printer to see what they have — it may help reduce the cost of printing a special piece.


Laser Engraving 

A second method of die cutting is laser engraving. With the use of a computer-controlled beam of amplified light for cutting, text and images are accurately reproduced on a variety of substrates. By using a laser to create die-cuts, manufacturers can provide exceptionally high quality, well-detailed, and fine-lined reproductions of intricate art, images, and corporate logos. Consider the following points:

• The laser has the capability of creating cut areas that are very small in size. Rotary and flat bed die-cutting cannot achieve the very fine detail of laser cutting.
• It is difficult to produce conventional dies for very small cut areas and it is difficult for the dies to strip away the paper from the small cut out areas.
• A laser engraved die cut can be created with the capability of reproducing an 800 dpi (dots per inch) image, allowing for a cut impression with a significant amount of clarity and definition.

Die-Cutting Tips

When determining whether a substrate is suitable for die-cutting or perforating, the following points should be considered:

• The thickness and firmness of the material.
• The stretch and elasticity, or spring back, of the material.
• The coatings or laminated components of the material.

In order to provide a high quality ("clean") die-cut or perforation, the following factors should be considered:

• The type of substrate that will be die-cut or perforated.
• The type of die and blades used for the cut or perforation.
• The cutting surface (hardened steel? compressible substrate?) on which the substrate will be placed during the process of die-cutting.
• The type of equipment that is used to apply the die-cut or perforation. 

Die cutting is good for edging off cards or making windows as you can't make a professional cut with scissor etc... This is some examples of some die cutting. I like how intricate things can be which mainly will be created through the laser cutter. And then the simplistic shapes so you can see through to the other page, like a window.