Die Cutting or Laser Cutting: Which Is Right for Your Labels?
Modern label production offers two methods for cutting labels to their final shape: conventional die cutting and laser cutting.
With conventional die cutting, a custom-made cutting die is mounted onto a die-cutting cylinder. As the material passes through the press, the die cuts each label to the required shape.
Laser cutting uses a highly precise laser beam instead of a physical cutting die. Because no tooling is required, virtually any label shape can be produced. The process is digitally controlled, offering maximum flexibility and efficient production, especially for custom designs and short runs.
Laser Cutting
Laser cutting is a modern finishing process that uses a precision laser to cut labels to the desired shape and size.
Advantages:
- Flexibility: no cutting die needs to be manufactured, allowing virtually any shape or size to be produced immediately.
- Price: laser cutting is generally more economical for short production runs, as it requires less setup time and less material for machine calibration.
Disadvantages
- White edges on dark designs: this mainly affects fully printed labels in dark colors such as black, navy blue, or dark brown. Depending on how the laser cuts the label, very fine white edges may occasionally become visible. On dark containers or bottles, this can affect the overall appearance of the finished product.
- Large formats: for large labels, two laser beams may be used during production. In rare cases, the point where the beams meet may not be perfectly aligned, creating a very small edge.
- Release liner markings: the laser may leave slight marks on the release liner, which can occasionally affect further processing.
Conventional Die Cutting
With conventional die cutting, a custom cutting die is manufactured to match the exact shape and size of the label. The die is then mounted onto a magnetic cylinder in the finishing equipment.
Advantages
- Suitable for all materials: there are virtually no restrictions on material choice. Papers, films, and thicker materials can all be processed, regardless of shape, size, or material thickness.
- Cost-effective for long runs: although setup takes slightly longer, conventional die cutting is generally more economical for larger production runs. Once production begins, it typically runs faster and more efficiently than laser cutting while consuming less energy.
Disadvantages
- Higher setup costs: conventional die cutting is typically more expensive for short production runs because a custom cutting die must be manufactured and additional setup time is required.
Get in Touch
The best cutting method depends on your specific requirements, artwork, and order quantity. If you’re unsure whether conventional die cutting or laser cutting is the right choice for your project, our team will be happy to help.