4 Basic Design Elements of Die Cut Parts

June 8, 2021

The die cutting process has been very helpful for the packaging industry. Through this process, workpieces are often cut out through a custom-shaped die. The die has sharp edges that enable it to cut the workpieces according to their shape and dimensions. Some of the most common materials that can undergo die cutting and can be cut by a die include paper, fibreglass, metal, and plastic.

This process has been around for decades. And as technology advances, more and more industrial applications can surely benefit from the die cutting process. For one, this particular process can achieve complex designs that other processes cannot easily generate. It can likewise make the entire production much easier given that multiple workpieces can be processed in just one go. Multiple layers of cutting are also possible with die cutting due to its flexibility. Many die cutting processes are even available to cater to a wide range of custom parts and products.

Die cut parts can boast different dimensions and styles. Additionally, they can contain varying design elements that would help them fulfil their purposes. These basic design elements are as follows:


Blanks are cuts that separate the part from the remaining workpiece material during the stripping phase. They often feature the edges of the finished part or product. During the part and die design, sharp internal or external corners must be avoided to prevent generating a stress point during the stripping and handling phases. Alternatively, rounded internal or external corners can make a part more durable.


Holes are another design element of die parts that feature empty spaces enclosed within the part’s boundary. These design elements can be produced through a punch or by a steel rule die. To avoid tearing during the stripping and handling phases, the hole must be placed at least double the material thickness from the edge. The clearance between the two adjoining holes, on the other hand, must be double the material thickness whenever multiple holes must be produced.


Folding and tearing processes can be done easily with the integration of scores. Scores can take the forms of cuts, creases, and perforations, making the previously stated processes to be so much easier. Additional stress points, however, might be generated in the finished part with scores. Hence, the hole needs to be not placed along the score line to prevent unnecessary tearing. A series of holes must likewise be placed fourfold the thickness of the material away from the score line.


Tabs, ultimately, are often integrated to attach edges and corners to the die cut parts. These attachments can provide die cut parts with three-dimensional features that are useful for a lot of industries. The tabs can be situated right outside the edge or confined within the plane. Holes that are generated on the tabs must be placed at least double the material thickness from the edge. The internal ends of the tabs, alternatively, must be terminated through a hole to effectively dissipate any stress.

To know more about these basic design elements of die cut parts, feel free to call us at Triforme.


Die Cutting: What Is It? How Does It Work? Parts, Design. (n.d.). IQS Articles. Retrieved May 24, 2021,

from https://www.iqsdirectory.com/articles/die-cutting.html


Get in touch

47 Vinter Ave. Croydon
VIC 3136
Email: design@triforme.com.au
Phone: +61(3)9723 4400

Optimized by NetwizardSEO.com.au