May 2004: Die Cutting Makes Products More Functional and Attractive

Die cutting can be used to create functional tuck flaps on product packaging (left), while high-die cutting enhances the design of this product hang tag (right)

If you're looking to add some pizzazz to your products, die cutting may be the solution. Die cutting is a versatile process that can be used to create tabs or flaps that make POP displays and product packaging more functional. It can also be used to enhance printed designs on book covers, packages, cases and direct mail pieces to make them even more attractive. The only limitation is your imagination!

Here are a few ideas for taking advantage of both functional and design-enhancing capabilities of die cutting:

Functional Applications
Product Packaging and POP Displays - Die cutting can be used to create easy-to-assemble displays, cartons and other product packaging. For example, die-cut tabs and slits can be used to form capacity pockets on POP displays or create cartons or boxes. End users can easily tuck these tabs or flaps, allowing the products to be shipped flat.

Expandable Pockets - A common complaint of capacity pockets - especially those in pocket folders - is that they are easily crushed when not filled. Die cutting can be used to create a pocket that expands when materials are placed inside, yet remain flat when empty. There are several different designs we can use that take advantage of die cutting to form expandable pockets and accordion gussets, so consult with The Riverside Group when planning your display or package.

Decorative Applications
Registered Die Cuts - Many intricate die cuts can be made even more impressive if they also register to a printed image underneath. At The Riverside Group, we can help you include die cuts that register to print on applications ranging from book covers and pocket folders to slipcases and slant cases.

Cards and Direct Mail Pieces - Die cutting opens up a world of marketing possibilities, allowing you to create cards, invitations and direct mail pieces in unique shapes that match your product, service, or promotional event. If direct mail is what you'd like to customize, note that the U.S. Postal Service has unveiled a new postal class, Customized MarketMail, that makes it possible to mail pieces in any shape you choose without an envelope. To learn more about Customized MarketMail, visit www.usps.com.

High-die cutting - Some small-format applications, such as product hang tags, call for die cutting to be performed around the perimeter of the piece. High-die cutting can be a great solution for these projects, as it allows smaller pieces to be highly customized.

The Riverside Group Advantage
At The Riverside Group, we can perform die cutting to help you achieve a nearly limitless range of objectives. For functional purposes, we can perform die cutting on a wide range of stocks, including synthetic paper, board up to 100 pt. (nearly 1/8" thick!), plastic, vinyl, poly and more. If a truly unique design is what you're after, we offer high-die cutting as well as half-cut and face-cut capabilities. Our multiple machines enable us to handle long runs, and our complete range of in-house post press capabilities means you can let The Riverside Group handle the entire production of your project, no matter how complex.