What is Die-Cutting?
Die-cutting is a mechanical process that cuts precise shapes from sheet material (paper, vinyl, cardboard, fabric, leather). A custom-shaped metal blade ("die") cuts the exact shape you design. It's used for:
- Custom vinyl decals
- Promotional stickers
- Business cards & postcards
- Packaging templates
- Labels & tags
- Bookmarks
- Appliqué shapes
- Custom patches
Die-Cut Line Requirements
The most critical aspect of die-cut files is the cutting line. This is different from regular artwork.
The Cut Line (Die Line)
The cut line is the vector path that defines exactly where the die cuts. Print shops have specific requirements:
Color: Specific Color Required
Usually cyan (0, 255, 255 in RGB) or a specific Pantone spot color. Ask your print shop which color they use for die lines.
Line Weight: Thin (0.5pt - 1pt)
The cut line must be thin and consistent. Use 0.5pt to 1pt stroke. Avoid thick lines – they won't cut accurately.
Stroke Type: Hairline or Registration
In Adobe Illustrator, use "Hairline" or "Registration" mark for the cut line. Set to "No Fill" and the cut line color as stroke.
Separability: On Its Own Layer
Put the cut line on a separate, clearly labeled layer. Some shops need to separate it from artwork for die creation.
Closed Paths Required
The cut line must form a complete, closed path (no breaks or gaps). A broken line won't cut properly.
- ✓ Good: Connected path with no breaks
- ✗ Bad: Broken lines or gaps in path
- ✓ Good: Simple, clear outline
- ✗ Bad: Overly complex, has self-intersections
Bleeds and Safety Margins
Understanding Bleeds
If your design has colors that go to the edge, you need "bleed" – extra color extending beyond the cut line.
Why Bleeds Matter
If the cut isn't perfectly accurate, you'll see white paper along the edge. Bleed hides this imperfection.
Standard Bleed: 1/8" (0.125")
Extend colors 1/8" beyond the cut line. This allows for slight cutting inaccuracy.
Safety Margin (No-Print Area)
Area inside the cut line where you shouldn't place important text or graphics. Allows for minor cutting variation.
Recommended safety margin: 1/16" to 1/8" inside the cut line
Example: For a 2" square sticker, keep important text/graphics in the 1.875" x 1.875" inner area
Common Die-Cut File Problems
Problem: "Artwork Extends Beyond Cut Line"
Your artwork (text, graphics) goes outside the cut line area.
✓ Solution: Keep all important elements inside the cut line with safety margin.
Problem: "Cut Line Color Wrong"
Cut line is black, blue, or wrong color.
✓ Solution: Ask shop which color they use for die lines, set cut line to that color.
Problem: "Cut Line Has Breaks"
The cut path has gaps or isn't a complete closed shape.
✓ Solution: Verify path is closed. Use Object → Path → Make Path in Adobe Illustrator if needed.
Problem: "No Bleed Included"
Design has colors to edge but no bleed for safety.
✓ Solution: Extend colored areas 1/8" beyond cut line to create bleed.
Step-by-Step: Creating a Die-Cut File
Ask Print Shop for Requirements
Get specifications: cut line color, bleed amount, safety margin, file format, die size limits
Create Your Artwork
Design as normal with artwork and graphics. Use CMYK color mode.
Add Bleed
Extend colored backgrounds 1/8" beyond where you want the cut to be
Create Cut Line Layer
On new layer, draw the cut line path. Set to required color (usually cyan). Make path 0.5pt - 1pt
Label the Layer
Name layer "DIE LINE" or "CUT LINE" so it's obvious to print shop
Verify Closed Path
Double-check cut line has no breaks. Use Object → Path tools if needed.
Save File
Export as .AI or .EPS with all layers intact
Include Specs Document
Send email with cut line color, bleed info, and any special instructions
File Format & Technical Specs
Recommended File Formats:
Adobe Illustrator (Best)
Preserves all layers and detail. Most print shops prefer this.
Encapsulated PostScript (Good)
Universal compatibility. Slightly less flexibility than AI.
Vector PDF (Acceptable)
Only if saved as VECTOR PDF, not image PDF. Ask shop first.
Technical Checklist:
- Color mode: CMYK (not RGB)
- Cut line: Correct color (ask shop)
- Cut line: 0.5pt to 1pt weight
- Cut line: Closed path with no breaks
- Bleed: Extended 1/8" beyond cut line
- Safety margin: 1/16" to 1/8" from cut line
- File size: Reasonable (under 50MB)
- All fonts: Converted to outlines
- No transparency: Flattened artwork
- Layers: Organized and labeled
Die-Cut Machine Types
Different cutting machines have different capabilities. Your design constraints depend on the machine your print shop uses:
Rotary Die-Cutting Machines
Up to 14" wide
Standard for small-medium products. Fast and cost-effective.
Flatbed Cutting Machines
Up to 48" x 60"
Larger designs possible. More expensive. Better for complex shapes.
Digital Cutting Machines
Varies by model
Silhouette, Cricut, etc. Can cut without custom die. More expensive per unit.
Plotter Cutting Systems
Large format
Industrial vinyl cutting. Good for simple shapes, logos, decals.
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