A Guide to Die-Cutting & Dielines in Print.
When it comes to custom packaging, labels, stickers, and creative print designs, precision is key. That’s where cutting dies come into play. At Impactica, we use various die-cutting methods to ensure your printed products look sharp, professional, and exactly how you envisioned them.
In this post, we’ll explain what a cutting die is, the different types of dies we use, and how to properly set up your dieline in an artwork file to ensure a smooth printing process.
What Is a Cutting Die?
A cutting die is a specialized tool used to cut, shape, or form materials—typically paper, cardboard, or vinyl—into specific, often custom, shapes. Imagine a cookie cutter, but for your print marketing materials. From unique business card shapes to intricately cut packaging, cutting dies make creative ideas come to life with precision and repeatability.
Types of Cutting Dies Used in Printing
Different die-cutting methods are used depending on the material, shape complexity, and production volume. Here are the most common types we use at Impactica:
1. Steel Rule Dies
Steel rule dies are one of the most traditional and widely used cutting methods for thicker substrates like cardstock, corrugated cardboard, and folding cartons.
• Construction: These dies consist of a plywood or composite board base with steel blades bent into shape and embedded into the surface.
• Best For: Medium to large production runs of packaging, folders, and other heavy stock items.
• Advantages: Durable, cost-effective for mid-volume runs, and capable of cutting complex shapes.
2. Flexible Rotary Dies
Rotary dies are cylindrical dies used in rotary die-cutting presses, often for high-speed and high-volume production.
• Construction: These flexible dies are magnetically mounted onto a cylinder and rotate in sync with the substrate moving through the press.
• Best For: Labels, stickers, and packaging—especially for long runs on thin materials.
• Advantages: Fast, consistent, and highly efficient for large production volumes.
3. Drag Knife Cutting (Digital Die Cutting)
Drag knife cutting is a digital process that uses a computer-controlled blade to cut through materials without a physical die.
• How It Works: A sharp blade "drags" across the material following a vector path.
• Best For: Short runs, prototypes, custom shapes, and intricate designs on materials like vinyl, paper, and thin plastics.
• Advantages: No need to produce a physical die, making it fast and affordable for one-offs or small batches.
What Is a Dieline?
A dieline is a digital outline used in the artwork file that shows where the die will cut, score, or perforate the final product. Think of it as the blueprint for how your design will be shaped.
Key Elements of a Dieline:
• Cut lines: Indicate where the material will be cut.
• Fold lines: Show where the piece will be creased or folded (usually dashed or dotted lines).
• Bleed area: Extends beyond the cut line to ensure there’s no white edge when trimmed.
• Safety margin: Ensures important text or images aren’t too close to the edge or fold.
How to Set Up a Dieline in Your Artwork File
1. Use Vector Software: Create your dieline in a vector-based design program like Adobe Illustrator.
2. Separate Layer: Place the dieline on its own layer, clearly labeled (e.g., “Dieline”).
3. Spot Color: Assign a unique spot color (e.g., 100% magenta or a custom-named color like “CutContour”) and set it to "overprint".
4. Use Proper Naming: If submitting to Impactica, follow our dieline naming conventions or reach out for a template.
5. Don’t Flatten: Keep dielines editable and vector-based—never flatten them into the artwork.
Final Thoughts
Cutting dies and dielines might seem like behind-the-scenes details, but they’re essential for producing high-quality custom print products. At Impactica.ca, we make it easy by offering expert guidance and templates to ensure your designs come out exactly right.
Whether you're designing custom packaging, die-cut labels, or creative promotional items, our team is here to help your vision take shape—literally.
👉 Have a project in mind? Contact us today to talk dielines, dies, and dynamic designs.
