Die cutting is an extremely versatile way to create unique results.

Die cutting, refers to the art of finishing your prints in a custom shape.

Custom die cut shapes on a business card, postcard, packaging, shelf wobbler, or even brochure cover help you stand out from the crowd and create unique and eye-catching pieces that are unique to you.

Due to their unusual shape, size, and appearance, die-cut products tend to attract more attention from customers. You can choose from simple finishes like rounded corners, to almost any custom shape.

To turn an ordinary marketing piece into an extraordinary solution that sets your brand and business apart from your competitors, we have two main processes for creating custom shapes on paper and cards - Die-cutting and Digital Die-less cutting.

We've included details below to introduce you to the pros and cons of each process. However, once you've read this, if you still have questions about setting up your files or the most convenient method, we're here to help. 

Digital Die-less Cutting 

What is digital die-less cutting?

Digital die-less cutting is most often used for small quantity custom shape cut orders. This may be for

• Prototyping purposes,
• Tight turnarounds, where there is not enough time to manufacture a die; or
• Small quantities where traditional die manufacture would not be is not cost effective

Die-less cutting is carried out on a flatbed cutter, where an oscillating knife and scoring wheel is used to cut around each shape individually. We can use this process to create anything from business cards, postcards, packaging, envelopes, signage, shelf wobblers, drink coasters, signage and more for you.

PROS:

• More cost effective for small volume orders
• Does not require the once-off cost of die manufacture
• Can start production immediately without waiting for a die plate to be produced

CONS:

• When the card is cut with an oscillating knife, there is a small burr along the edge, and some coining can be seen from the back.
• Fibres/cracking may be visible on the fold line of scored/folded items that have not been laminated

Rotary Die-Cutting Cutting

What is Rotary Die-cutting?

Die Cutting requires the manufacture of a die plate, which essentially acts like a high-tech cookie cutter. Printed sheets are fed through a rotary die cutting machine at high speed, so thousands of small items can be quickly cut out.

In addition to creating fully shape-cut products - such as marketing cards, business cards, and door hangers - scoring and perforating can be incorporated with your die to create more complex finished products like boxes & packaging, bottle neckers, tear-off cards, and thousands of other items. We can even adjust the die specs to create kiss cut stickers that peel off to your desired shape.

PROS:

• Dies last a long time and will be a one-time expense for most customers, being available for immediate use after your first order.

• Faster turnaround (after the initial die manufacture)

• Capable of fulfilling large volume orders quickly

• A crisper finish than die-less cutting

• More cost effective for larger or ongoing orders. 

CONS:

• Requires an initial investment to have the die made to your project specifications

• 4-5 day turnaround for your first order (subsequent orders are available as quickly as "same day" depending on specifications)

Common outcomes with short run Digital Die-Cutting and Die-less Cutting

Coining / Bevel (Raised Edge 1 side)

Coining / Bevel is a raised edge (see image below), it is called this as it is a bit like the end result of a minted coin,  like the outside edge on the circumference of a $1 coin so to speak.

It is a result of the blade of the die or the blade in our die-less cutting process where the blade / knife is pushed through 1 side of the stock to cut it. 

The above image illustrates the potential coining and chipping of uncoated card stock with dark coverage and die-less cutting. This design would be best executed by die-cutting, using a coated card stock, and possibly adding laminate to the card stock. 

Make no mistake, we certainly understand and appreciate that your your looking for the ideal product to represent your brand as we are also trying to find solutions to provide this solution for you and we always aim for producing a high quality commercially acceptable outcome, while also trying to offer you affordable solutions.

Although we would like to raise a couple of things for your consideration when choosing the right solution.

While we and you are looking at your die-cut product in a somewhat micro level picking up every stain in the carpet so to speak.  We can very confidently say in the 15 years that we have been in printing and die-cutting that 95+% of your clients won't even notice and even those who notice, we would say 98% of them would not blink an eyelid if there was a small amount of coining or fluffy edges.