What are Die-cut Decals? Types, Benefits, Drawback and Applying Process

Die-cut decals are decals that use dies to cut the decals into shapes (and sizes) specifically required by the product, packaging, manufacturer and/or user. Dies are tools that are usually custom-designed for specific shapes and cuts. They can be considered tools used for the sake of precise cuts in the decal material. However, some techniques allow manually cutting the decal materials using the dies.

Types of Die-Cutting:

While there are many types of die-cutting techniques that are used to make custom die-cut decals, the most commonly used include:

Flatbed Die-Cutting – This process involves the use of a flatbed die and press. The dies are designed according to the required shapes and sizes that press into the decal materials to cut the decals according to the required configurations. This process uses hydraulic lifting and pressing mechanisms to produce desired shapes. This process is used for smaller quantities because of the slower cutting speeds.

Rotary Die-Cutting – This refers to the use of cylindrical dies used, together, with a rotary press. This process uses a fast-moving (rotating) circular die that cuts through the decal materials. It is one of the faster die-cutting processes that can cut large quantities in short periods of time. It is, also, more cost-effective in comparison to some of the other techniques.

Semi-Rotary Die-Cutting – The die moves in clockwise and anticlockwise directions in a to and fro motion. This divides the individual decals into the required shapes. This process is faster than flatbed die-cutting and slightly slower than rotary die-cutting.

Benefits of Using Die-Cut Decals:

Durability – They are usually made with materials that are stronger. Also, the coloring process uses support pigments that make the coloring hard to fade.

Clean and Defined Cutting – The die-cutting process gives the decal cleaner and well-defined shapes and outlines.

Contrasting or Complimenting the Background – Since there’s no white space (unlike in kiss-cutting techniques), the decal can be made to appear as a part of the product or can be used to provide a sharp contract, depending on the requirements.

Promotion And Branding – They can be used to make the product stand out and be memorable. They can be used as giveaways at events or as an effective means of dispelling information.

Ideal For Customization – Since they are used to create purpose-built dies, they are ideal for use in situations when customization is the goal.

Some Drawbacks:

Complicated and Costly – Since die-cut decals printing require the creation of customized dies that are then used to cut the decals into shape, the production process is longer, more complex and costly in comparison to other cutting techniques such as kiss-cutting.

Ideal for Smaller Quantities – Since die-cutting takes more time than other decal production methods, they are considered ideal for smaller quantities.

Not Ideal for Designs That Use Acute Angles and Sharp Corners – This may result in tears and, hence, wastage.

Application:

Die-cut decals are versatile, and therefore, have a large number of applications:

• Boxes
• Bumper Stickers
• Giveaways
• Bottles
• Medical Instruments
• Musical Instruments
• Food and Beverages
• Apparel