A Cutting Die is necessary for the creation of custom boxes. Its purpose is to cut out the exact, specific shape and dimensions of your packaging.
The Cutting Die:
This tooling is required for anything that uses flat sheets like paperboard or foam. This generally means custom boxes, i.e. folding cartons, rigid boxes (set-up boxes), or corrugated boxes (including temporary POP displays – “Point of Purchase” displays)
These dies are composed of metal strips called “rule”. The rule is sharpened for cutting through the paperboard (or chipboard or corrugated fiberboard) or left slightly dull for scoring areas used for the closing flaps of the folding carton for example, and any other areas where the box will naturally fold.
The foam is used to hold the paperboard in place, keep it from tearing, and to assist in the punching out or stripping of the cut areas of the box.
So once the paperboard has been printed on (with your packaging graphics etc) it is then brought to a cutting machine where your cutting die (the tooling you paid for) is mounted.
Then it will be pressed against the printed paperboard where your customized box shape will be cut out and defined. The excess board that is stripped away is recycled (considered post industrial waste in the world of packaging recycling).
And here’s the folding carton box that was cut-out by the mounted die shown above:
Some packaging manufacturers make their own dies “in-house” or pay another company to make it for them. Below is an image of a cutting die in progress. These dies are handmade, with machine assistance, of course.
Some printing machines have a cutting and gluing component build into them. In those cases, the die cutting is said to be done “inline”. All this means is that the printed paperboard doesn’t have to be physically moved to a separate machine or assembly line for die cutting, as it’s all done on the same machine. In either case, of course, a customized cutting die is still required.
So, as you might expect, once the cutting die is made and you decide to change something about your custom box that alters the specifications of it, a new die has to be made.
Cutting dies are standard in the world of custom boxes (folding cartons, rigid boxes, corrugated/shipper boxes, POP displays). Don’t be surprised by them. Everywhere you go for custom box packaging a cutting die will be required (except with very low volumes where your boxes would be CAD cut instead).
This has been a part of my tutorial series called How to Buy Packaging 101. So click the link below to head back if you haven’t finished reading it yet. 🙂
4 Responses
Hello Sara
Do you have any idea how much does a cutting die last? I mean how many paperboard can cut before need replacement or knife change?
And what is the cost average of one 100 x 70 cm die?
Thanks
Hi Mauricio,
A paperboard cutting die is as little as $200 to $800 depending on how much cutting rule is used and how intricate it is. For this size of a cutting die, probably between $250 – $500US or less would be my best guess.
I intended to purchase a “tooling” die for our in house corrugated box making.
How much will it cost me to have/adopt the conventional type (use of jigsaw and benders).
Your prompt reply is very much appreciated
Custom tooling depends on how big and how much rule is needed, and also the type (meaning is it for a rotary press or flat bed). However, I wouldn’t be surprised if your cutting die was anywhere from $800-$1200. A jig/benders will add more money easily.