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Metal Dies
A sharp metal die, custom-made for the label design, is mounted onto a die plate.
How Traditional Die Cutting Works
Traditional die cutting uses precision-engineered metal dies to create labels in virtually any shape or size. This time-tested process ensures consistent results for everything from standard designs to highly intricate patterns.
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Cutting Process
The die presses into the material, cutting through the face stock and adhesive while leaving the release liner intact.
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Physical Tooling
Requires a unique metal die for each design, making it ideal for repetitive or custom shapes.
Advantages of Traditional Die Cutting
Traditional die cutting delivers speed, cost-efficiency, and reliability, especially for high-volume orders. Its versatility allows for a wide range of materials and shapes, making it a trusted choice for consistent label production.
01
High-Speed Production
Perfect for large-scale orders with fast throughput.
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Cost-Effective for Large Runs
Die costs are spread over high volumes, reducing per-label costs.
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Material Compatibility
Handles various materials with consistent results.
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Reusable Dies
Metal dies can be reused for repeat designs, saving time and money.
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Simplicity and Reliability
Best suited for a range of shapes, including intricate and detailed designs.
Challenges of Traditional Die Cutting
While traditional die cutting is highly effective, it does come with some limitations. These include upfront tooling costs, material waste, and reduced flexibility for frequently changing designs.
01
Upfront Costs
Creating custom dies can be costly for intricate or one-time designs.
02
Design Flexibility
Limited to fixed shapes; frequent changes require new dies.
03
Material Waste
Aligning printed labels with the die tool during the finishing process requires extra running meters for calibration. This leads to increased printing and material usage, resulting in additional waste.
04
Setup Time
Longer setup compared to digital methods, impacting short runs.
Applications of Traditional Die Cutting
Traditional die cutting supports a diverse range of applications, from custom-shaped labels to high-volume production runs. Its adaptability makes it suitable for industries with repetitive designs or unique labeling needs.
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Custom Shapes
Perfect for intricate, highly detailed designs that stand out.
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High-Volume Orders
Ideal for industries such as food and beverage, logistics, and cosmetics requiring mass production.
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Repetitive Jobs
Efficient for recurring designs, ensuring consistency across multiple runs.
Sustainability in Traditional Die Cutting
Traditional die cutting can support sustainable production with reusable dies and compatibility with eco-friendly materials. However, managing material waste and recycling worn-out dies remain key challenges for manufacturers.
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Advantages
Reusable dies and compatibility with eco-friendly materials.
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Challenges
Material waste and worn-out dies, though recycling options are available.
Best Practices for Traditional Die Cutting
Maximizing the benefits of traditional die cutting requires thoughtful planning and design. By optimizing processes, combining techniques, and prioritizing sustainability, businesses can achieve high-quality, efficient results.
01
Consolidate Designs:
Where possible, optimize designs for production efficiency.
02
Plan for Volume
Maximize cost-effectiveness by using traditional die cutting for large runs.
03
Recycle Dies
Partner with manufacturers offering die recycling programs.
