December 2007—Ensure Your Die Cutting Projects Go Smoothly

Die cutting is a versatile finishing method used to create a wide range of products including presentation folders, table tents, direct mail pieces, and this time of year, holiday cards! For just about any design that needs cuts beyond what can be achieved on a flatbed cutter, turn to your die cutting professional for the right solution.

For eye-catching pieces consider die-cutting

Like other finishing and bindery processes, successful die cutting depends on good planning and clear communication for production to go smoothly. Perhaps that’s why a designer’s best friend may be an experienced die cutting services partner.

Consult with your die cutter about complex designs before commitments are made so you don’t waste resources on an overly intricate piece only to be disappointed by an unexpected limitation.  This especially hurts if a simple phone call could have prevented the problem. Die cutting is a fairly straightforward operation if you play by the rules but once that ink hits the paper, it’s an extremely expensive proposition to make significant changes. With today’s high-tech graphic arts production machinery, the sky seems to be the limit for designers who routinely plan complex projects, sometimes without verifying that their vision is practical.

We want to avoid this scenario: 1) Great design. 2) Great printing. 3) Last minute workaround measures necessary to keep costs as expected.

Production Tips

• Steel rule dies have their limits: Steel die cutting blades can only bend so far. Excessively sharp angles can not be achieved by bending steel rule. This can be achieved by creating mitered joints but this will create a weak spot in the die, running the risk of die failure at that particular point. When pushing the physical bending limits of steel, the thickness of the blade can be an issue.

• Stripping out paper waste: For designs with small internal stripped out die cuts, such as lattice work, be aware that you might have stripping issues, regardless of whether the appropriate machinery has automatic stripping capabilities.  The result might be partially stripped pieces with dangling waste in some areas, akin to the hanging chad voting problem in 2000 or an intricate part of the piece is torn while the waste is being removed.

• Show all the complexities: If you are working on a project with an intricate die cut design, show your finisher everything you have early in the design stage, including the angles and radiuses.

• Stay within the boundaries: Allow at least 1/2 ” gripper margin, and clearly mark it on your sheet.  As in printing equipment, the gripper is where the die-cutiing press grabs the sheet and pulls it through the press.

• Space between images: Make sure there is a reasonable amount of room between your die cut images. When there are too many images laid out on a sheet, your finisher might have additional challenges maintaining cut to print registration.

The Riverside Advantage
Located in Rochester, New York, The Riverside Group is a leading provider for a broad range of binding and finishing services including perfect and PUR adhesive binding, case binding, mechanical binding, die-cutting, folding, gluing and attaching, UV coating, foil stamping and embossing, laminating and much more. From large runs to handwork, our skill and expertise shows in our attention to detail and exceptional customer service. Contact us today to discuss your next project.