Structural · 2 min read
Designing for Die Cutting
How to set up dielines, bleed, scores and grain direction for die-cut pieces and folding cartons, and the design choices that keep dies and make-ready simple.
Die cutting turns a printed sheet into a shaped product: a folding carton, pocket folder, display component or hang tag. The steel rule die is built from the dieline, so the dieline is effectively a manufacturing drawing. Whenever possible, start from a dieline supplied by your finisher or engineered in CAD for the specific stock. Carton dielines account for board caliper in panel dimensions, glue flap sizes and tuck clearances. A dieline drawn for 18 pt board will not fit correctly in 24 pt, and a generic template downloaded online may not match the dies your finisher already has on the shelf.
File setup
- Supply the dieline as vector art on its own layer, in a named spot color, set to overprint and marked as non-printing.
- Differentiate cut, score, perforation and crease lines by color or line style, and include a legend.
- Extend bleed past every cut line. An 1/8" bleed is common as general guidance; confirm the requirement with your finisher.
- Keep critical copy and graphics inside a safe area away from cuts and folds.
- Indicate grain direction on the dieline, especially for cartons and anything that folds.
Structure and material
Grain direction affects how cleanly a sheet scores and folds and how stiff a carton panel stands. On most folding cartons the grain runs perpendicular to the main folds, but the right orientation depends on the construction. Scores need to suit the caliper: too shallow and the board cracks or springs back, too deep and it can cut through. On heavier board and coated stocks, a crease matrix or counter shapes a clean hinge. Tight internal corners, narrow slots and very small holes are hard on both the rule and the stock. Radius internal corners where you can, and keep features away from the sheet edge and from each other so waste strips cleanly and the nicks that hold the sheet together can be placed where they will not show.
If you are developing a new structure, send C&H the dieline or a description of the piece. We can review it, build a CAD layout and cut a sample before it goes to production.
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