Die cutting is used in repeatable, high-volume production runs of parts such as gaskets, seals, and packaging inserts. Compared to other cutting methods like water jet cutting or machining, it enables precision over high-volume orders, but can have initial startup costs worth consideration. The two principal types are:
- Rotary Die Cutting: Ideal for thin, flexible materials (up to around 0.015″ thick) and large production runs. A cylindrical die continuously cuts as the material feeds through rolling cylinders.
- Flat Bed Die Cutting: Suited for thicker or denser materials (up to around 0.5″ thick) and moderate volumes. A flat die presses down on the material, offering a broader range of cut depths.
Understanding how each cutting method can fit into a manufacturer’s supply chain comes from knowing each one’s strengths and weaknesses.
Die Cutting vs. Other Machining Methods
| Method | Process | Best For | Material Limitations | Typical Thickness Range | Strengths | Considerations |
| Rotary Die Cutting | Cylindrical dies cut material as it passes through rolling cylinders. | High-volume production of thin, flexible materials (e.g., adhesives, foams, films, gaskets). | Limited to thin materials; not ideal for rigid or thick substrates. | Up to ~0.015″ | Fast, repeatable, low per-unit cost at scale. | Requires custom dies (tooling cost); not suitable for intricate or varying-depth cuts. |
| Flat Bed Die Cutting | A flat die applies pressure downward to cut through material. | Moderate-volume runs of thicker or rigid materials (e.g., dense foams, rubber, packaging inserts). | Less effective for very thin materials that require continuous feeding. | Up to ~0.5″ | Handles a wider range of materials and thicknesses; lower initial setup cost than rotary for small runs. | Slower cycle times compared to rotary; tooling change required for design modifications. |
| CNC Machining | Computer-controlled milling or turning removes material to shape a part. | Low- to mid-volume production of precision parts requiring 3D features (e.g., metals, plastics, aerospace components). | Not ideal for simple, high-volume 2D shapes due to slower processing speeds. | Varies widely (~0.001” to 6”+ depending on material and machine type). | No tooling costs; excellent for prototypes and small batches. | Slower and more expensive per piece compared to die cutting at scale; limited in handling very thin materials efficiently. |
| Water Jet Cutting | High-pressure water (often with abrasive) cuts through material. | Thicker or heat-sensitive materials (e.g., metals, composites, stone). | Can be slower for high-volume runs; some materials require secondary finishing. | Typically up to ~3”+ | No heat-affected zones; suitable for thick or hard materials. | Higher operational costs; not as fast or efficient for thin, flexible materials. |
| Laser Cutting | A focused laser beam melts or vaporizes material along a programmed path. | Precision cutting of detailed or intricate designs (e.g., metal components, signage, electronics enclosures). | Less effective on thick or heat-sensitive materials. | Up to ~0.5” (varies by laser type and material). | High precision; no physical tooling required; quick design changes possible. | Can generate heat-affected zones; cost per part may be higher for large-scale production. |
Specific Advantages and Considerations for Die Cutting
Pros of Die Cutting
| Efficiency in High-Volume Production |
| Die cutting is particularly effective for large-scale manufacturing, allowing for rapid and consistent production of parts. |
| Precision and Consistency |
| The process ensures uniformity across all produced parts, maintaining tight tolerances and high-quality standards. |
| Versatility in Design |
| Die cutting can accommodate complex and intricate designs, making it suitable for a wide range of applications. |
| Cost-Effectiveness for Large Runs |
| The per-unit cost decreases significantly in large production runs, making it an economical choice for bulk manufacturing. |
Considerations for Die Cutting
| Initial Tooling Costs |
| The creation of custom dies can take several days and add expense, which may not be justified for small production runs. |
| Material Choices |
| Die cutting is most effective with certain materials and may not be suitable for very thick or hard materials. |
| Design Modification Constraints |
| Once a die is created, any design changes require the production of a new die. |
When to Consider Other Cutting Methods
While die cutting is often the most cost-effective option, especially among thinner materials, it is certainly not the best fit for all applications. Below we’ve compiled the principal industrial cutting methods and some examples of best-fit projects for them, and where die cutting would make more sense.
| Cutting Method | Best Suited For | Where Die Cutting Should Be Considered |
| Water Jet Cutting | Thicker plastics (e.g., polycarbonate panels for industrial machine guards) | Die cutting is better for thin plastics like lens protectors or flexible display covers, where speed and precision at scale matter. |
| CNC Machining | Aluminum housings or rigid enclosures requiring 3D shaping | Die cutting excels for flat aluminum EMI/RFI shielding where high-volume, consistent cuts are needed. |
| Laser Cutting | Intricate, low-volume metal components (e.g., custom decorative panels) | Die cutting is better for repetitive, high-volume metal foil parts such as battery insulators or gaskets. |
| Plasma Cutting | Thick metal parts like structural steel or automotive brackets | Die cutting is preferred for thin conductive films or metalized plastics, where excessive heat from plasma could damage the material. |
| Stamping | High-volume metal components (e.g., automotive body panels) | Die cutting is ideal for non-metallic gaskets, insulation layers, and rubber seals, where precision cutting without deformation is required. |
| Router Cutting | Large-format composite panels or signage requiring varied depths | Die cutting works better for uniformly thin materials, like pressure-sensitive labels or membrane switches. |
| Slitting/Converting | Continuous rolls of adhesive tapes or foam padding | Die cutting is preferable when individual shapes (e.g., gaskets, seals, or cushioning pads) are needed instead of just straight cuts. |
| EDM (Wire Cutting) | Complex, high-precision metal tools or dies | Die cutting is better for soft materials like foams and textiles, where speed and scalability are more critical than ultra-fine precision. |
Handling Different Material in Die Cutting
For manufacturers that are considering die cutting, it’s important to note that material choice can significantly alter a project’s timelines and achievable tolerances for parts. The choice of material is crucial in die cutting, as it affects the quality of the cut, the durability of the die, and the overall efficiency of the process.
Foams
- Open-Cell Foams: These are soft and compressible, making them suitable for die cutting. However, their flexibility can pose challenges in achieving clean cuts, especially with rotary die cutting.
- Closed-Cell Foams: Denser and more rigid, closed-cell foams are better suited for die cutting, particularly with flat bed die cutting, which can handle their thickness and density more effectively.
Plastics
- Thermoplastics (e.g., PET, PVC): These materials are generally suitable for die cutting, offering clean cuts and maintaining structural integrity.
- Thermosetting Plastics: Due to their rigidity and brittleness, these plastics may present challenges in die cutting and may require specialized dies or alternative cutting methods.
Rubbers
- Natural Rubber: Its elasticity can make die cutting challenging, as the material may deform during the process. Proper die design and cutting parameters are essential to achieve clean cuts.
- Synthetic Rubbers (e.g., Neoprene, EPDM): These materials often have more consistent properties, making them more amenable to die cutting. However, their hardness and thickness must be considered to select the appropriate die cutting method.
Fibers and Fabrics
- Woven Fabrics: The interlaced structure can lead to fraying during die cutting. Utilizing sharp dies and appropriate cutting techniques can mitigate this issue.
- Non-Woven Fabrics: These materials typically cut cleanly and are well-suited for die cutting processes.
Adhesives and Tapes
- Pressure-Sensitive Adhesives (PSAs): Die cutting PSAs requires careful handling to prevent adhesive buildup on the die, which can affect cut quality and die longevity.
- Double-Sided Tapes: These can be challenging to die cut due to their stickiness. Specialized dies and release liners are often used to facilitate the process.
Metals
- Thin Gauge Metals: Materials like aluminum or copper foils can be die cut, but they require robust dies and significant cutting force. The hardness and thickness of the metal will dictate the feasibility and method of die cutting.
Choosing the Right Die Cutting Partner
Selecting a die cutting partner requires assessing expertise, equipment, and production capabilities. A reliable provider ensures precision, scalability, and material compatibility while maintaining efficient lead times and strict quality control. Below are key factors to evaluate when choosing a die cutting supplier.
| Versatility in Cutting Capabilities | A partner should offer both rotary die cutting (for thin, high-volume materials) and flat bed die cutting (for thicker materials up to 0.5″). This ensures flexibility in material selection and production needs. |
| Experience & Engineering Expertise | A strong supplier has years of experience optimizing die designs, material selection, and production efficiency across industries like automotive, medical, and electronics, reducing waste and improving performance. |
| Precision & Tolerance Control | Tight tolerances are critical for component compatibility. A reliable partner invests in digital inspection, registration control, and documented processes to ensure consistent, accurate cuts. |
| Scalability & Production Capacity | High-volume orders demand efficient, repeatable production without delays. The best partners scale output smoothly while offering rapid prototyping and tooling adjustments for custom components. |
| Material Expertise & Customization | Some materials require specialized handling. A knowledgeable provider understands adhesives, foams, and rigid substrates, offering customization like kiss-cutting, laminations, and multi-layer construction. |
| Logistics & Supply Chain Reliability | A well-connected supplier ensures fast lead times, consistent raw material sourcing, and cost-effective shipping—minimizing disruptions while keeping production efficient. |
| Commitment to Quality & Compliance | For industries with strict standards, a partner should retain detailed inspection records, and be able to confirm traceability to meet aerospace, medical, and automotive requirements. |
Final Thoughts
Die cutting can be an extremely economical way to make precision components out of thinner materials, especially for companies looking to scale their supply chain. To learn more and see whether or not integrating an experienced die cutting partner into your production pipeline makes sense, fill out the contact form or call Colvin-Friedman Vice President Josh Rodman at (707) 769-4488.