Die-Cutting
The die-cutting process is a popular manufacturing technique within the packaging and greetings card industry. It involves the use of a cutting die, or forme as it is often called, that is loaded in to one of our die-cutting machines. Using significant pressure, the die is stamped in to the sheet to cut out all the shapes required on that design. The process is essentially a giant cookie cutter that is pressed into the material to form the desired shape of the product.
The ability to mass-produce custom products is where the real value of the die-cutting process lies. Die-cut packaging is easier, faster and more cost-effective to create custom packaging at a larger scale.
Here’s a step by step guide to the process of generating a cutting forme.
1 – Keyline or profile line is created from the designer
2 – Keyline design file is sent to our laser cutting machine. The laser machine cuts out the Forme board and marks which areas need to be cut, perforated or creased
3 – Our in-house forme maker adds the knives and foam to the board to complete the die
4 – Forme is ready to be used in a die cutting machine!
By altering the depth of where the blade lies inside the foam, you can achieve more than just cutting. It may seem like a simple process but forme making for the most part is hand made, time consuming and is a real craft. We have a full time forme maker on hand in our workshop to create, fix and adjust formes for our customers. This is essential to ensure we have minimum downtime on the machine, and allows us to very fine-tune the die to produce the best finished product.
A variety of cutting rules can be used in the die-cutting process. Each rule has its own function and its use depending on the complexity of the packaging.
Some of the most common rule options are:
Through Cutting: Through cutting cuts through the packaging material.
Scoring: Rather than cutting the whole way through the material, scoring leaves an impression indent or partial cut on a single stress point.
Creasing: Creasing is similar to scoring where the die creates a fold line on the packaging material. Unlike scoring, creasing allows for inward bending of the material by having two parallel stress points. Havings two stress points allow for greater flexibility of the material.
Perforating: Perforating involves indenting a line of holes along the design material. The design is not separated from the material itself but can easily detach along the perforated lines.
Keyline or profile created by the designer. We have studio support with this if required.
A selection of cutting formes, showing the front and reverse of the die
Our in-house workshop is a fantastically skilled area of the business. Crafting and creating cutting dies by hand.