Converting & Assembly
Die Cutting
Custom shapes, windows and crease lines cut precisely in one pass to give packaging its structure.
What it is
Die cutting uses a custom steel-rule die to cut the sheet into its final shape and crease fold lines in a single pass. It is how cartons get their structure, tags get their outline, and cards get windows and slots. ZKPACKS supports die cutting for folding cartons, mailers, tags, cards and inserts, including kiss-cut and crease-only work.
How it looks
Clean custom outlines, openings and precisely folded structures.
How it feels
Sharp, clean edges with consistent crease lines that fold smoothly.
Verified media pending
A media slot—not a fabricated factory image.
Add ZKPACKS sample close-ups, before/after comparisons or verified production media when source and process attribution are confirmed.
Suitable materials
- SBS paperboard
- CCNB
- Kraft paper
- Corrugated board
- Cover paper
Suitable packaging types
- Folding carton boxes
- Hang tags
- Paper cards
- Packaging inserts
- Corrugated mailers
Recommended combinations
- Die cutting with window patching
- Die cutting with packaging gluing for carton assembly
- Die cutting with v-grooving for sharp-edged rigid structures
Artwork requirements
- A precise dieline with cut, crease and perforation lines distinguished
- Bleed extended beyond the cut line
- Minimum material bridges respected between adjacent cut elements
Limitations
- — Each custom shape requires a dedicated die with tooling cost
- — Very intricate or tightly nested shapes can weaken the structure
- — Deep crease lines need board with enough caliper to fold cleanly
Production risks
- — Die wear over long runs causing rough edges or inconsistent creases
- — Misregistration between print and cut on complex shapes
- — Paper tearing at sharp corners or tight radius points
Sustainability considerations
Die cutting is a mechanical converting step that adds no material, so paper-based board may be recyclable subject to material specification and local collection infrastructure.
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