Die Cutting
Optimized & Industry-ready Solutions
For All Your Complicated Needs
Die-Cutting is the process of converting materials into identically shaped pieces by utilizing a die: a ‘stamp’ consisting of sharp blades. The raw material is first mounted on a plate and then run through the machine, where the die is pressed onto the material, creating the desired shape. The speed of the machine and uniformity of the die allows identical products to be mass-produced at a rapid rate. The process also uses custom made dies, so virtually any shape can be die-cut from a material. CGS also utilizes a more sophisticated kiss-cutting technique. It involves cutting through just one layer of material, stopping at a laminated layer or liner, allowing for paper-thin cuts.
01.
Flat Bed Die Cutting
Flatbed die cutters use a powerful hydraulic press to drive a steel rule die down onto the material, piercing it cleanly and forming precise shapes. This method is highly versatile and compatible with a wide range of materials including foams, films, gaskets, plastics, and adhesive-backed substrates. It is the most popular die-cutting method due to its lower tooling costs, making it especially cost-effective for shorter production runs, prototyping, and custom jobs where the high initial investment in rotary tooling may not be justified.
Flatbed die cutting is ideal for thicker or multi-layer materials, as it delivers strong cutting pressure and can maintain high tolerances. It's also well-suited for larger part sizes or intricate designs that would be difficult to execute with rotary systems.Specifications
Max width up to 24″
Tolerances of up to +/- 0.005″, varies with material
02.
Rotary Die Cutting
Rotary Die-Cutting uses a precision-engineered cylindrical die mounted on a rotary press. A continuous roll or long sheet of material is fed through the press, where the die rotates in sync to cut, kiss-cut, or perforate the material at high speeds. This method is significantly faster and more efficient than flatbed die-cutting, making it ideal for high-volume, continuous production runs.
Although rotary tooling costs more upfront, it becomes cost-effective over time as the expense is diluted across larger quantities. The time savings, increased throughput, and automation potential make it the preferred choice for long runs, especially in industries like medical, automotive, electronics, and consumer packaging.
Rotary die-cutting also enables multi-station capabilities, such as laminating, scoring, waste removal, and slit cutting—all in a single pass—further boosting efficiency and reducing labor.
Specifications
Max size of 12″
Tolerance of ± 0.005″, varies with material
Flatbed vs. Rotary Die-Cutting – Key Differences
| Feature | Flatbed Die-Cutting | Rotary Die-Cutting |
|---|---|---|
| Speed | Moderate | Very High |
| Tooling Cost | Lower | Higher |
| Ideal For | Short runs, large or thick parts | Long runs, small or thin parts |
| Tolerance | ± 0.010" (typical) | ± 0.005" or better |
| Material Thickness | Supports thicker and multi-layered materials | Best for thin, flexible materials |
Converting Requirements?
Whether you have a rough idea or a detailed spec, we're here to help. Contact us today and let's bring your vision to life.
Die Cutting Materials
Die cutting is ideal for a variety of materials because of its efficiency, including:
Markets Served
Many industries benefit from the use of die cut materials, because it saves time and money. For example:
- Electronics
- Automotive
- Medical
- Specialty industries Manufacturing
- Powder Coating
- Aerospace
Benefits of Die Cutting
High Precision and Consistency
Die-cutting offers extremely accurate and repeatable cuts, ensuring every piece meets exact specifications. This is especially important for applications requiring tight tolerances or intricate designs.
Material Versatility
Whether you’re working with paper, plastic, foam, rubber, or specialty films like polyimide, die-cutting can handle a wide range of materials with ease—making it suitable for many industries including electronics, packaging, and automotive
Speed and Efficiency
Die-cutting is a fast, automated process ideal for large production runs. It significantly reduces production time compared to manual cutting, allowing for quick turnaround without compromising quality.
Cost-Effective Production
With minimal material waste and reduced manual labor, die-cutting is a cost-efficient method. Once a die is made, it can be used for high-volume production, lowering per-unit costs over time.
Questions
Frequently Asked Questions
What’s the difference between kiss-cutting and through-cutting?
Kiss-cutting slices through only the top layer of material (such as adhesive tape or label stock), leaving the backing liner intact—perfect for peel-and-stick products. Through-cutting, on the other hand, cuts through all layers of the material, fully separating the shape from the sheet or roll.
Can you die-cut adhesive-backed materials?
Yes, we specialize in die-cutting a wide range of adhesive-backed materials, including 3M tapes, foam adhesives, films, and specialty laminates. Our equipment handles both kiss-cutting and full cuts depending on your application needs.
Do I need to provide a CAD file?
If you already have a CAD, DXF, or PDF file of your design—great! If not, no problem. Our in-house design team can work with your sketches, measurements, or samples to create precise die layouts tailored to your application.
How long does it take to produce a new die?
Standard steel rule dies typically take 1–3 business days to produce. For more complex rotary dies, lead times may range from 5–10 business days, depending on design and material
What is your minimum order quantity?
We offer flexible production volumes. For flatbed die-cutting, we can accommodate prototypes and small runs. For rotary die-cutting, a higher MOQ is generally recommended due to tooling cost. Let us know your quantity, and we’ll advise the most cost-effective option
Get In Touch
(905)836-6668
Canada: 1119 Ringwell Drive, Newmarket, ON, L3X 2H8
USA:2221 Kenmore Ave Buffalo, NY 14207, USA
Email info@cgstape.com