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  • Jason Mills

Your One-Stop Guide for Die Cut Packaging

Updated: Nov 30, 2021

Are you looking for a box that perfectly fits the dimensions of your products?

Then die cut packaging is the way to go.

Within the packaging sector, die-cutting is a typical production procedure. It includes cutting materials into a range of package styles and shapes with the use of a die.

The capacity to mass-produce unique packaging is where the die-cutting technique adds significant value. Creating personalized packaging on a bigger scale is faster and more cost-effective using die cut packaging.

We’ll look at the die-cutting technique and its significance in bespoke packaging in this post.

What Is Die Cut Packaging?

Many companies prefer die-cutting custom packages because they can be designed to form around the various shapes of your products. These are constructed with a pre-built cutter that is customized to your specifications. It operates similarly to a cookie-cutter in that it presses your design onto a corrugated board sheet. Die cutting began as a method of letterpress printing and has since evolved into a more specialized industrial technique.

It’s most commonly employed in the production of folding carton packaging, but it’s not restricted to that.

Businesses utilize die-cutting to produce one-of-a-kind custom packaging that is personalized to their brand storytelling and customer experiences. It is a highly beneficial technique since it is easier, faster, and more cost-efficient to produce customized packaging in larger quantities. As a result, each box is distinct from the others. It’s the design flexibility that allows them to fit around your product precisely.

What Is The Die Cutting Process?

A die is a specialized instrument that is used in a press to cut and shape packing materials. A box die may be thought of as a ‘mold’ fashioned in the exact shape required to cut out your bespoke package.

Computer-Aided Design (CAD) is usually used to create a digitized drawing of the package outline. This template is then transferred to a die board (typically a piece of hardwood).

The most advanced approach for sketching designs onto die boards is burning a pattern onto the hardwood surface with state-of-the-art laser cutters. Due to the exact nature of lasers, before beginning the die cutting process, make sure you have the cut lines, fold lines, bleed lines, and safe zones precisely marked out on your die line.

Since the advent of laser cutters in the die-cutting process, more accuracy and precision have been possible when producing die boards. Die boards rest beneath the material to guarantee little movement and precise positioning while cutting for more precision during the die-cutting process. Once the blade has made an incision through the material, the die boards effectively function as a guide, keeping the cuts square and exact.

While cutting is the name of the game, die-cutting serves a variety of purposes, including:

  • Through cutting - box die cuts directly through the material.

  • Scoring - leaves an imprint or indent on a specific region.

  • Creasing - generates a fold line to make building easier.

  • Perforating - creates a succession of little holes that may be easily torn apart.

Each of these functions has a purpose for various types of packing materials and structural designs.

Steel rules and a variety of foam and rubber bits are hammered into the die board to guarantee the die bounces off the corrugated board during manufacturing. This makes the crease lines stand out and create a lasting imprint, making folding easier.

The die-cutting machine firmly pushes the die into the material to cut out the custom cut cardboard and perform its programmed tasks.

Die Cutting Techniques

Die cutting boxes is still a laborious process. Despite the use of technology, the fastest technique for mass-producing bespoke packaging is still using a manually constructed cutting die.

In packaging, the two most common die-cutting processes are:

Flatbed Die Cutting: Flatbed dies are created by cutting a flat, rectangular piece of hardwood into the desired form.

It utilizes a flatbed machine pressing a cutting die into the cardboard.

Due to the limited blank size of flatbed die machines, they are not recommended for bigger designs. They can, however, create delicate, precise patterns like little cut-outs, tight cuts, and split scores.

Rotary Die Cutting: Unlike the flatbed die cutter, rotary cuttie dies are created using a cylindrical press and rolled over the material rather than pushed down.

Die packaging using a rotary die is a significantly faster procedure that is excellent for mass manufacturing basic patterns.

Some rotary die-cutting machines, for example, can laminate and emboss at the same time.

While capable of generating larger volumes at a faster pace, rotary cutting machines aren’t always the ideal solution.

The technique/machine utilized is determined by the packaging’s design and required functionality.

What Are The Benefits Of Die Cut Boxes?

Die cut boxes come in handy a lot, especially if you want to display your product in a visually attractive manner. Here are a few reasons why you should utilize die cut boxes to package your products:


Die cut cardboard is economical to bulk manufacture. You can order large quantities for a reduced price.

Simple to store

Die cut boxes are simple to store because they are flat and arrive unassembled. This is particularly beneficial because they can be put together on demand.

Easy to assemble

Advanced skills aren’t necessary to put together die cut boxes. This is crucial for businesses, as an organization that has to send out large-scale mailings must be able to quickly assemble boxes.

Your boxes are cut with a laser

Die cuts can customize these boxes to accommodate any product size or form.

Costs of delivery are reduced

Because custom die cut boxes are made specifically for your goods, they require less packaging material in the case of delicate or fragile items. The delivery costs for bespoke die cut boxes are much lower than those for other materials due to these material features.

Your brand receives more exposure

Your company’s logo and marketing phrases are etched on these boxes, highlighting the importance of your goods at every turn. You can make a stunning and unique design for your product packing box to give that extra spark to your product’s exposure without having to pay exorbitant advertising costs.

Delicate items are better protected

Because a die can custom cut any product to fit its size, your customers don’t have to worry about their items getting thrown around inside an oversized packaging.

It is environmentally friendly

Choosing environmentally-friendly materials for your packaging will help the environment and boost your company’s reputation. Selecting a reputable professional box company will provide you with the most possibilities when constructing your personalized boxes.

Choose Epic Packaging

Epic Packaging is committed to providing full-service, custom package solutions that increases the sales of our customers. If you want to learn more about die cut packaging and how it can help your business, contact Epic Packaging today.

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