How Die Cut Packaging Techniques Has Changed The Packaging World

These days it is all about the packaging rather than the product itself because it is the only thing a customer sees at the first instance regarding a product. Companies are coming up with unique and different ways of packing their products to get customers involved with the brand on a deeper level. Packaging has been the reason for creating a lot of spark in the market and among the customers. People actually take out time to take a look and appreciate the packaging of products, if they are well designed.

Die cut boxes have been a new sensation in the market as they give the most outstanding and captivating containment with ultimate protection and other packaging benefits such as;

  • Grabbing the attention of the customers
  • Marketing of the products
  • Aesthetic appeal to the products
  • Protection against damage

Die cut packaging allows making shapes of any kind because of the process that is used in manufacturing and techniques that gives various types of designs.

Without any more ado let us see how it works in getting the shapes that have no match in their uniqueness.


The process involves cutting the material with a machine that is called die-press. This process involves many steps and the most paramount is the first one, that is ;

Making Of A Die

Die is a plate made up of different materials from aluminum alloy to pre-hardened steel. This plate goes into a die press to cut the material of choice in the desired shape. There are a lot of methods used to make dies such as vacuum forming, bending, blanking, broaching, and bulging, which depends on what type of material is used to make a die.

Not to forget that quality of die cut boxes depends on the quality and accuracy of the die. Custom dies allow manufacturers to make the boxes in any shape no matter how complex or odd it is, such as;

  • Window cut-outs
  • Pillow boxes
  • Gable boxes
  • Folding encasements


These custom made dies are used to knife irregular shapes out of the sheets such as cardboard, paperboard, and corrugated cardboard. It is important to have sharp edges to get the cut in the single press for more defined and accurate cutting, which gives the most high-end custom die cut boxes.

Scoring & Creasing

It is the process of pressing a crease into the paper sheet which allows it to fold accurately on the defined lines.

Wide number of complex shapes for die cut boxes can also be attributed to incorporating creasing into the die cutting rather than on a separate machine like other processes. Incorporating creasing of custom die cut boxes in the cutting process gives accuracy and consistency in the design.

Folding And Assembling

It is the final stage that finally gives die cut boxes their shape. As the name implies, these scored sheets are folded onto the creases to form a box.


Die-cutting process can be used in various ways to adorn packaging boxes in the most extravagant manner such as;

Negative Technique

This technique involves solid images. Dies of the required images are nested into the machine that cuts accordingly giving a very fine and accurate edge.

Inlaid Die-Cuts

This technique requires a minimum of two cuts. It involves the cutting of die in the background paper material and then again in the paper of the image. After that, the die cut from the background is removed followed by replacing it with the die-cut of other color paper material.

Knock-Out Technique

This technique does not cut a positive shape. Instead, it cuts small pieces that are impossible to use alone. This is another variant of negative technique.

Window Technique

As the name implies, this technique does not cut on the outer edges but the inner ones making a hole or window. These windows can be made in every shape and size.

Selective Cut

It is the most unique method of making cut outs for stylish and luxurious boxes. It involves cutting of selective material and leaving the rest as it is.

The process combined with various techniques gives outstanding and remarkable packaging boxes that are one of its kinds.

Now it is easy to understand why these boxes are called die cut boxes. This process of making custom die cut boxes in unique shapes is beneficial in a lot of ways for the companies such as;

  • Custom die cut boxes are highly customizable in terms of printing which gives more professional outlook
  • Die cut packaging does not need additional taping or gluing for assembling
  • Die cutting gives consistent die cut packaging because of custom dies
  • Custom die cut boxes in wholesale is the most efficient and cost-effective way to get boxes of every style.

Not only style and affordability die cut packaging offer sustainability and durability which make these boxes the most loveable by the companies and the customers as well.

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