What are Die Cut Labels?
Jun 19, 2025|
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Die cut labels are adhesive label products where the face material and adhesive layer are precisely cut into shape using custom-made dies, while keeping the backing paper intact. This process allows labels to be peeled off individually, making them widely used in product identification, packaging, industrial labeling, and custom stickers. As a core technology in modern packaging and printing, label die cut ensures perfect adhesion to various containers and curved surfaces, balancing production efficiency with complex design requirements.
I. Core Process of Die Cut Labels
The essence of die cut labels lies in semi-penetration cutting—dies precisely cut the face material and adhesive layer without damaging the silicone coating on the backing paper. This requires precise alignment of pressure, blade angle, and material properties:
Flatbed Die Cutting: A flat die plate presses parallel to the platform. Low cost and flexible, ideal for small batches of complex designs. However, slower speeds may cause backing paper cuts or waste breakage due to pad wear or dull blades.
Rotary Die Cutting: Uses cylindrical die rollers for continuous high-speed cutting (over 100 meters/minute). Magnetic die plates allow quick pattern changes but require regular gear and blade maintenance to avoid precision loss.
Laser Die Cutting: Contactless digital cutting. Computer-controlled lasers vaporize materials without physical dies, enabling instant pattern switching. Ideal for short runs, curved designs, variable data labels, and anti-counterfeiting micro-cuts.
II. Technological Evolution: Precision and Efficiency Breakthroughs
Recent advancements in label die cut technology enhance performance through intelligent systems and structural innovations:
Dynamic Correction Systems: High-precision cameras locate registration marks (replacing traditional sensors), achieving 0.02mm repeat accuracy and auto-compensating for material stretch.
Differential Tension Mechanisms: Patented designs (e.g., CN118386311A) apply variable tension before/after cutting to prevent misalignment from material slack.
High-Speed Transfer Optimization: Patents like Dalian Xingtong’s (CN222387008U) use feed buffer tables, compression units, and slide grooves to minimize jams and boost continuous production.
III. Production Challenges and Technical Solutions
Waste Stripping is the most critical challenge, especially for irregular shapes prone to lifting or label dragging:
Enhanced Tensile Strength: Laminating waste edges or adding back-knife cuts creates a "face + backing" dual layer to prevent breakage.
Peel Force Control: Silicone coating weight strictly maintained at 0.1–2g/m², ensuring peel force between 1–10g/N for smooth waste removal.
Environmental Management: Temperatures below 8°C cause backing paper brittleness (winter heating required); static control needed for film materials.
Quality Testing: Peel a label and apply water-based ink to backing paper indentations. No penetration indicates incomplete adhesive cutting; ink seepage means silicone layer damage. Ideal results show clear indents without seepage.
IV. Material Innovation: Meeting Demanding Applications
Modern label die cut demands advanced materials:
Backing Paper: Tensile strength 65–310MPa, shrinkage 8%–50% (e.g., PETG) to prevent jagged edges during wrapping.
Face Material: Tensile strength 65–310MPa, shrinkage 5%–45% to ensure wrinkle-free application on cylindrical items like batteries.
Optical Positioning: Pre-printed ≤50mm×5mm light-sensitive zones aid automated application, fully concealed post-wrapping.
V. Future Trends: Digital Die Cutting Meets Industry 4.0
Rising demand for small-batch customization makes laser die cutting ideal for digital printing:
Databases store cutting parameters for different materials, enabling "one-click material switching";
Integrated PDF workflows support 300+ daily short-run orders.
Meanwhile, AI-powered vision systems will improve defect detection and automation, paving the way for "unmanned die-cutting workshops."
Die cut labels are not just labeling solutions—they embody the fusion of precision engineering, material science, and digital innovation. As a leading label die cut provider, Ameida integrates flatbed, rotary, and laser die cutting with patented tension control and intelligent correction. Delivering ±0.1mm precision, we empower global brands—from anti-counterfeiting traceability labels to custom-shaped stickers—to elevate their packaging.
Application Examples:
Electronics: 0.05mm-precision laser-cut flexible circuits (FPC);
Creative: Holographic/glitter stickers, 50-piece minimum orders;
Industrial: Weather-resistant vinyl labels (-40℃~80℃ adhesion).
