Digital Die Cutting

What is Digital Die Cutting?

So what do we mean when we say large format digital die cutting? It’s a process where a blade or router bit cuts large sheets of digital media into finished pieces on an industrial plotting machine.

In other words, it cuts your project into any size and shape.

For our online printing services, we primarily use a Zund digital die-cutting system to finish your product to perfection. Thanks to its Swiss engineering, the Zund executes with precision and speed. Other machines simply can’t match the functionality, quality or available tooling options.

Digital Die Cutting: Any Shape, Any Size, Any Time

With this premium feature, we’re not talking just simple circles, ovals or rectangles. Think any shape specific to your business or industry: abstract logos, wine bottles, food shapes for grocers, instrument shapes for school programs, etc.

Smartpress Tip: As you’re designing your projects, remember that the smaller your dimensions and detail, the more the die cutting quality decreases. For example, cutting finite detail inside a 1” x 1” square may be challenging depending on the thickness of the material and the level of detail required.

How Does Digital Die Cutting Work?

No matter what your project is, this feature produces the shape you need. Here’s how:

The Digital Die Cutting Process in 4 steps:

1. A digital file of the cut paths and cut methods is prepared and sent to a server where it is called forward by one of our Zund operators.
2. The file includes all directions and cut layers for each of the cutting methods specific to your job.
3. The file also includes a register layer to orient the sheet placement on the cutting bed to the cutting beam and toolheads.
4. Our operator uses a camera to locate the registration marks printed around the perimeter of the art and the cutting begins.

Die Cutting vs. Laser Cutting: What’s the Difference?

Digital die cutting and digital laser cutting are such similar terms, it’s easy to get them confused. The simplest way to differentiate them is by the cutting process.

As we mentioned above, die cutting is for our large format products and uses the Zund’s knife or router to cut them.

Laser cutting is for our small format products (business cards, brochures, cards, etc.) and features a MotionCutter laser digital die-cutting system. Here, the laser cuts paper stocks and other thin, flat materials.

Laser Cutting Pros

• Swift cutting method
• Fast job changeover
• Extremely precise
• Wide array of cut methods
• Can cut many different materials
• Lack of setup fees makes it a cost-effective design option

Laser Cutting Cons

• Can cut only one sheet at a time
• Limitations to thickness and density of some materials

How to Set Up Your File for Die Cutting

You may be asking yourself how should I set up my file for die cutting and laser cutting? Watch the video below to learn how in Adobe Illustrator or InDesign.

How to Add Digital Die Cutting to Your Project

You can add it to your project in two ways:

Option 1

If you see a Digital Die Cutting dropdown on the product page (shown below), select which type of die cutting you’d like. Please provide a dieline of your artwork for specific shapes on your print-ready file.

Option 2

If you do not see a Digital Die Cutting dropdown on the product page, simply provide a dieline of your artwork for specific shapes on your print-ready file.

Tips & Tricks

• When submitting your print-ready file, a clean, minimal vector point dieline is best.
• The cut itself can become choppy if too many points are used to create a vector dieline.

Die Cutting vs. Laser Cutting Key Takeaways