Die cut foam and tape in packaging industry

Die cut parts play a crucial role in rapid production, offering precision and efficiency across various industries. Whether you’re in packaging, electronics, or automotive manufacturing, die cutting can be a cost-effective solution. But what exactly are die cuts, how do they work, and how do you determine if they are suitable for your product? This guide will walk you through the fundamentals of die cutting, different methods, benefits, pricing, and how to get started.

What are die cuts?

Die cutting is a fabrication process that uses specialized machinery to cut, shape, or perforate materials into specific forms. A die, which is a custom-made tool, applies pressure to a material—such as foam, plastic, metal, or paper—to produce precise cuts. This process is widely used in creating gaskets, labels, protective packaging, and many other products requiring uniformity and accuracy.

A poron produced by die cut technology at New Edge 

The different types of die cutting

Each die cutting technique offers distinct advantages depending on the material, production volume, and precision required. Below is a comparison of the most common methods:

Die cutting method	How it works	Best for	Advantages	Limitations
Flatbed die cutting	Uses a hydraulic press to stamp out shapes from sheets of material.	Thicker materials, small to medium production runs.	High precision, cost-effective for short runs.	Slower than rotary cutting, not ideal for high-volume production.
Rotary die cutting	Uses a rotating cylindrical die to cut materials continuously.	High-speed, high-volume production of thin materials.	Fast, efficient, and great for large runs.	Higher initial die costs, not suitable for thicker materials.
Kiss cutting	Partially cuts through adhesive-backed materials, leaving the backing intact.	Tapes, stickers, labels, and adhesive components.	Easy to peel and apply, precise cuts, thin material.	Limited to thin adhesive materials, not for non-adhesive materials.

A kisscut machine with high precision was equpited to serve electronic packaging industry at New Edge

Why you should choose die cuts

Die cutting offers several advantages that make it a preferred manufacturing method:

• Efficiency – high-speed production with minimal material waste.

• Consistency – ensures uniformity in every piece, which is critical for mass production.

• Cost-effectiveness – reduces manual labor and speeds up production time.

• Versatility – can be used on various materials, from soft foams to rigid plastics.

• Customization – allows for intricate designs and tailored solutions.

Die cut could help improve consistency of products through the precision of die cut machines and die mold - Die-cutted cleaning sponge produced by New Edge

How die cut pricing works

Die cut pricing depends on several factors, including:

• Material type – thicker, high-quality materials cost more than thinner, standard ones.

• Complexity of design – simple shapes are cheaper to produce than intricate patterns.

• Production volume – large orders typically reduce the cost per unit by saving on die investment costs and labor expenses for machine setup and operation..

• Die creation costs – die costs vary depending on the type of product. 

• Processing method – rotary and kiss - cutting may cost more due to precision and speed advantages.

How to get started

If you’re considering die cutting for your production needs, here are the steps to get started:

• Assess your product requirements – identify the material, shape, size, and quantity you need.

• Choose the right die cutting method – determine which type best suits your production volume and material.

• Find a reliable die cutting partner – work with a manufacturer that specializes in your industry’s needs.

• Request prototyping – if needed, test a sample run to ensure quality and precision.

• Optimize production costs – discuss bulk order pricing and potential cost-saving measures with your supplier.

How New Edge offers you the best die cutting solutions?

New Edge is a leading provider of die cutting services, particularly specializing in the packaging industry. Our state-of-the-art die cutting solutions ensure that your packaging is not only precisely cut but also optimized for durability and efficiency. We work with a wide range of materials, including foams, plastics, and corrugated boards, allowing us to cater to a variety of packaging needs. Whether you require protective inserts, custom-shaped packaging, or intricate designs that enhance product presentation, our expert team ensures every piece is crafted with precision.

At New Edge, we prioritize quality and efficiency, leveraging the latest die cutting technology to handle both small and large production runs. Our modern flatbed, kiss-cutting and digital die cutting capabilities mean that we can accommodate complex designs without compromising on speed. Additionally, we focus on sustainability, minimizing material waste while maximizing the effectiveness of your packaging solutions. With a commitment to customer satisfaction, we offer tailored consultations to understand your unique requirements and provide cost-effective solutions.

A die-cutted foam producing for bike packaging by New Edge

With nearly two decades working in packaging industry in vietnam, New Edge provide converting die cutting processes for all our customers. Our comprehensive approach ensures that each project is handled with precision and care. Our process includes the following steps:

• Discussing your product design – we collaborate with you to understand your packaging needs and requirements.

• Researching die cutting methods – we determine the most suitable die cutting technique for your product.

• Preparing the die cut mold – we create high-quality molds to ensure precise cutting.

• Die cutting – we execute the cutting process efficiently, maintaining high accuracy.

• Packing your products – we ensure that your products are securely packaged and ready for distribution.

Currently, we provide die cut products such as tape, foam, eva, and plastic for high-tech industries in ho chi minh city, serving electronic companies with precision-cut components. We are actively supplying businesses in saigon hi-tech park and vsip industrial parks in southern vietnam, ensuring top-tier die cutting solutions tailored for advanced manufacturing needs. Additionally, we export die cut foam products overseas to countries like Netherlands, USA, Uk, Japan, and more. This extensive reach allows us to deliver high-quality solutions with competitive pricing. Whether you need domestic or international supply, New Edge is committed to providing you with the best service and value.

Conclusion

Die cutting is a game-changing technology for the packaging industry, offering improved efficiency, precision, cost savings, design versatility, and enhanced safety. By incorporating die cutting into your production process, you can achieve higher quality outputs while reducing waste and operational expenses. As the demand for innovative and customized packaging solutions continues to grow, investing in die cutting technology can provide your company with a competitive advantage in the market. At New Edge, we are committed to providing high-quality die-cutting services to meet all of your packaging needs. Contact us today to start a successful partnership and enhance your production efficiency with our expert die cutting solutions!

P/S: New Edge News