Die Cutting Process Explained: Step-by-Step Guide with Diagram

Die cutting uses a precision-shaped die to cut materials at exact tolerances, repeatably and at scale. This guide covers:

Die Cutting Techniques

Choosing the right technique starts with your material. Design complexity and production volume determine what comes next.

Rotary Die Cutting

Rotary die cutting mounts cylindrical dies on rotating rollers. Material feeds through the machine continuously while the dies cut shapes at speeds up to 40,000 units per hour. Each pass runs multiple operations simultaneously, eliminating additional processing steps:

• Cutting
• Laminating
• Slitting

Rotary die cutting achieves tolerances as tight as ±0.005 inches. It works best for thin, flexible substrates under 0.015 inches:

• Films
• Foams
• Tapes and adhesives

Flatbed Die Cutting

Flatbed die cutting presses a flat die onto sheet material in a start-stop cycle. It handles thicker, more rigid substrates that rotary cutting cannot accommodate:

• Rubber
• Foam
• Rigid composites
• Certain metals

Flatbed supports material widths up to 40 inches at tolerances of ±0.010 inches. Production capacity runs 2,000 to 4,000 parts per hour depending on part size.

Steel Rule Die Cutting

Steel rule die cutting shapes a steel blade into your design profile, embeds it in a wood or metal base, and presses it against the material. It suits new designs and lower-volume runs, particularly those with straightforward geometries. Average tooling cost runs $100 to $500, compared to $500 to $2,000 for rotary tooling. This cost difference makes steel rule the practical starting point for prototypes.

Kiss Cutting

Kiss cutting scores material to a precise depth without cutting through the backing layer. It applies to any adhesive part that requires clean separation from the liner, including labels and peel-and-stick gaskets.

Matching Your Material to the Right Method

Material type dictates the cutting method and the tolerances achievable.

Material	Preferred Method	Common Applications
Plastics (PET, PVC, Polycarbonate)	Flatbed (thick sheets) / Rotary (films under 0.015″)	Electronic insulation Medical device components Packaging
Foams (Open-cell & Closed-cell)	Rotary (thin gaskets) / Flatbed (thick padding)	Automotive gaskets Medical padding Industrial insulation
Rubber (Neoprene, EPDM, Silicone)	Flatbed (thick sheets) / Rotary (thin seals)	Gaskets Vibration dampeners Aerospace and HVAC sealing
Paper & Cardstock	Rotary (high-speed) / Flatbed (specialty)	Packaging inserts Custom labels Printed materials
Tapes & Adhesives	Rotary (roll-to-roll)	Electronics bonding Automotive assembly Medical adhesives
Metal Foils (Aluminum, Copper at or under 0.015″)	Rotary (ultra-thin) / Flatbed (slightly thicker)	EMI shielding Conductive gaskets Aerospace heat shielding

Three additional factors determine which method fits your project:

• Tolerances: Rubber and foam compress under load. Tighter process control maintains dimensional accuracy.
• Adhesive backings: Tapes and films with adhesives affect liner selection and kiss-cut performance.
• Durability requirements: Aerospace and medical components demand materials with high resilience under load.

The Die Cutting Process: Step by Step

A successful die cutting project starts with careful design and ends with quality-checked, production-ready parts. Here’s what happens at each stage.

Step	What Happens	Key Activities
1. Design	The team reviews your specifications and prepares the design for production. Engineers build or refine a prototype and test it functionally before moving forward.	Die type selection Material selection Finishing requirements Prototype development and testing
2. Die Creation	Die toolers fabricate the die from high-grade steel, focusing on sharpness and dimensional accuracy for reliable performance throughout the production run.	Die fabrication Dimensional accuracy Tooling quality
3. Machine Setup	The operator mounts the die, calibrates pressure, and aligns the material. CAM (computer-aided manufacturing) software establishes tight tolerances and helps minimize material waste from the first cycle.	Die mounting Pressure calibration Material alignment CAM setup
4. Quality Approval	Initial samples undergo QMS (quality management system) review before full production. Customers may also test samples at this stage.	Tolerance tests Dimensional checks Fit-and-function tests Design adjustments
5. Production	The die cuts the desired shape from the material. Rotary lines run continuously, while flatbed presses operate in cycles. In-process checks maintain consistency throughout the production run.	Rotary or flatbed cutting In-process inspection Consistency monitoring
6. Post-Processing	Cut parts are de-nested and undergo any required finishing. Excess material is collected and reclaimed where possible.	Lamination Adhesive application Final inspection Material reclamation

Colvin Friedman’s Production Capabilities

Colvin Friedman has operated rotary and flatbed die cutting lines from its Petaluma, California facility since 1949.

Category	Rotary	Flatbed
Maximum Product Width	16 inches (larger jumbos slit down)	40 inches
Maximum Product Thickness	0.015 inches	0.5 inches
Tolerance Level	±0.005 inches	±0.010 inches
Maximum Production Capacity	40,000 units/hour	2,000–4,000 parts/hour
Average Lead Time	3 weeks	3 weeks
Average Initial Tooling Cost	$500–$2,000	$100–$500

Die Cutting vs. Other Cutting Solutions

Die cutting isn’t the right solution for every application, but for many thin-material, high-volume projects, it offers advantages over alternative cutting technologies.

Alternative	Why Die Cutting Wins	Example Application
Laser Cutting	Faster and more cost-effective for high-volume runs	Automotive gaskets: Die cutting can outperform laser cutting in speed and material efficiency.
Waterjet Cutting	More efficient for thin, non-metallic materials	Disposable filtration media: Die cutting delivers consistent output at high volume.
CNC Routing	Better suited to large-batch production of thin, flat materials	Electronic insulation films: Die cutting delivers fast, high-precision cuts with minimal tool wear.
Plasma Cutting	Ideal for non-metallic substrates, while plasma excels at thick metals	Foam cushioning inserts: Die cutting handles various foam densities at production speed.

Further Reading

• Rotary Die Cutting: Full specifications and capabilities
• Flatbed Die Cutting: When to choose flatbed over rotary
• Steel Rule Die Cutting: Cost-effective cutting for simpler geometries
• Custom Die Cutting: Colvin Friedman’s full process from consultation to production
• Die Cutting vs. Laser Cutting: A side-by-side comparison of both methods