The Surgery Is Now Open

Hi Max,

I wish I had to do projects like that in school – makes a change from boring old algebra! You’re absolutely right – die-cut packaging is a common term in our industry because it is a key product of the bespoke corrugated world.

There are two main ways to manufacture boxes: the first is an inline process, where a piece of board is fed through a machine with individual wheels and blades, effectively spitting out a readily cut and scored box. This method is typically used for standard stock products, as the right sizes are already programmed into the machine, allowing for high-volume production.

The second method is die-cutting. This involves creating a large 'stamp' made from several blades that is pressed firmly into the board by a machine capable of applying pressure—known as a flatbed press. There's also another type called rotary die-cutting, where the die (CAD design) is mounted on a cylinder and rolled over the board. This is more suitable for producing large quantities of packaging efficiently.

The advantage of die-cutting is that, using a CAD (Computer-Aided Design) system, practically any shape or style of box can be created. This makes it ideal for custom orders where a carton needs to fit a specific product perfectly. Box dimensions are usually based on internal measurements, as that’s where the product sits, while external dimensions vary depending on the thickness of the board.

Additionally, die-cutting allows for the inclusion of various closures and special features, such as self-locking bases that speed up the packing process or tamper-evident seals for security. These details make die-cut packaging not only functional but also visually appealing and highly customizable.

Many of these designs are featured in the FEFCO (The European Federation of Corrugated Board Manufacturers) style guide, which includes over 900 box styles. While these can be adapted to meet specific requirements, the guide serves as a great starting point for designing a unique and professional-looking carton.

Good luck with your project, and don’t hesitate to ask if you have more questions!

The Packaging Doctor

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