What is Die-Cutting 

& Die-less Cutting?

If there's one obvious way to stand out, it's daring to be different. With our custom shapes and sizes, we can ensure that your custom prints and design will have a matching custom shape too for your unique marketing and branding purposes. Check out the wide range of options you have for die cut prints.

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

When we mention die-cutting, we refer to the art of cutting out intricate shapes in one clear-cut swoop, with the usage of metal cutting shapes called dies. This is to achieve the custom shape you desire for your printed products.

A die cut business card, postcard, brochure, book cover or even product packaging has the advantage of being unique and eye-catching helping you stand out from the crowd creating unusual pieces that are unique to your brand.

Die-cut products are often more aesthetically pleasing and likely to intrigue customers because of their unusual shape, size, and appearance. Shapes can range from a simple card with rounded corners, pop-ups, reveal windows to an intricate piece with fine details.

We have 2 processes in-house including our Rotary Die-cutting process and also our digital die-less flatbed cutting process to help you turn an ordinary marketing piece into an Extraordinary solution that helps to set your brand and business apart from your competition. 

If you or your designer still need help trying to figure out how to prepare your designs for die cutting on any product, we’ll be glad to assist you.

Digital Die-less Cutting 

What is digital die cutting?

Digital die cutting works without the use of a metal-cast die like our die-cutting process basically it is a computer driven tools that can be knives / blades for cutting systems but our system also includes tooling for scoring and other applications.

It is not only great for creating prototypes before the investment in a custom die, it's ideal for short run and quick turnaround solutions where the investment in a die is not needed and or you don't have the time to allow 2-3 extra business days for the custom die to be made.  

We can use this process to create anything from business cards, postcards, packaging, envelopes, signage, shelf wobblers, drink coasters, signage and more for you.

Please note that with our die-less cutting process there can be a very small burr on the reverse of the cutting side. The large majority of our clients are fine with it as it saves the investment in a custom die which for something like this would be around ($350-400+gst) and even larger majority of their clients would not even notice 

Rotary Die-Cutting Cutting

What is Rotary Die-cutting?

Rotary die cutting works with the use of a flexible metal laser cut die on our Horizon RD-4055 Rotary Die-cutter.

The dies is manufactured by our die-manufacture in which we can incorporate thru-cuts, kiss cuts, creasing and perforation solutions to turn a plain printed sheet into a custom size and virtually any shape producing a range of solutions including custom shaped business cards, marketing cards, tear off cards, postcards, boxes, Box sleeve, Coffee cup wraps, kiss-cut and die-cut stickers, envelopes, table signage, shelf wobblers, drink coasters and a lot more . 

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. 





Depending on the stock and the product coining can be more predominant in our die-less cutting process and for us to minimise the coining outcome,  you would need to consider our die-cutting process. Although an important consideration with choosing die-cutting over our die-less cutting process is that you will need to invest in a custom die which can  start from $220 plus GST for a small and simple die but can increase very quickly with more complex and larger dies and this excludes the printing and die-cutting process.

However the great thing about the die-cutting process is that once the die is made majority of clients find that it is generally a once off cost as we keep it on file for future orders and unless your producing in the 10's to 100's of thousands and then it becomes a consumable and realistically a great challenge to have 

'Fluffy' Edges

Fluffy’ edges are more common for paper and card stocks. The fluff happens when the blade cuts through and hits the jacket and isn’t quite sharp enough to make a 100% clean cut through the material. The cut then leaves the edges of the material frayed or ‘fluffy’.

It is important to note that frayed / fluffy edges are much more noticeable in a stack, it is rarely noticed when each product is view in isolation. While we aim to ensure it is very minimal if there is any fluffy edges resulting, if you receive your job and it happens to have some of the fluff. More often than not it easily removes with a light brush stroke of your finger along the edges. 

While we do have ways to reduce this as dies get older by increasing the pressure of the cut, putting on new jackets and ultimately replacing the dies, dies are not a once off consumable and it is a balance between a "commercially acceptable" outcome and the cost of continually replacing dies. While we would all like things to be absolutely perfect 100% it is the balance the age old business challenge of ROI. When you have invested in a custom die it will be your decision what you believe is acceptable, and like us, like paper, like almost everything it is almost impossible to be perfect all the time. 

'Chipping' Edges

As a result of the short run commercial digital printing processes we use and the way die-cutting and die-less equipment / processes we use work we highly recommend that you consider laminating (Cello-glazing) all die-cut products especially for solid colours and or images to the trim edge otherwise chipping can occur on one side of your product.

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 adn 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.




Best for cutting out shapes

Reduce the costs of dies required for cutting patterns


Good for making creases in card paper and plastics

Reduce material waste

Product Packaging

Custom Product Shapes

Can cut all type of thickness i.e Very thick or thin


Good at cutting many layers

Accurate cutting is possible

Custom Shape Boards


No cutting by hand or with templates.







Drink Coasters



Bottle Neckers



Door Hanger & Car Hangers




Our Summa F Series F1612 Flatbed Cutter

1 - Summa F Series F1612 63in Flatbed Cutter
2 - Summa F Series F1612 63in Flatbed Cutter
3 - Summa F Series F1612 63in Flatbed Cutter
4 - Summa F Series F1612 63in Flatbed Cutter
5 - Summa F Series F1612 63in Flatbed Cutter
6 - Summa F Series F1612 63in Flatbed Cutter

Our Horizon Die-Cutter

Looking for more Marketing Inspiration?

Call Us