What is a label cutting die? Steel rule types, heights and layouts

What is a label? The layers of a self-adhesive label

A label is a printed piece applied to a product, carton or pack to carry its name, contents, barcode, price or warnings. Most labels that are cut with a steel rule die are self-adhesive: they arrive on sheets or rolls with a pressure-sensitive adhesive already in place. The way to understand this material from the die’s point of view is to look at its layers.

• Face stock: The top layer that carries the print. It can be coated paper, uncoated paper, thermal paper, kraft, PP, PET, vinyl or metallised film.
• Adhesive: The thin layer under the face stock. It is chosen as permanent, removable, freezer-grade or for a specific surface; its thickness and flow directly affect how the cut edge behaves.
• Silicone coating and liner: The release carrier that lets the label peel off easily. It can be glassine, kraft or PET. In a kiss-cut, this is where the rule has to stop.
• Varnish or laminate: A protective layer over the print. It adds to the total thickness being cut and can change how the edge cracks.

By use, labels are called product labels, barcode labels, price labels, shipping and logistics labels, shelf labels, promotional stickers or custom-shape logo labels. By production method they fall into two groups: sheet labels, printed and cut as individual sheets, and roll labels, printed and cut from reel stock and usually applied by a labelling machine or printer. How the die is built differs clearly between these two groups.

Non-adhesive paper and board labels are cut the same way; there is no liner, and the label is separated completely. Board tags tied to a product with string or a plastic fastener have their own service page: hang tag cutting dies.

What are label cutting dies and label rules?

A label cutting die consists of steel rules bent and set into channels cut in a base board, with ejection rubber bonded around the rules. When the press closes the die onto the material, the rules cut the label contours and the rubber pushes the material back off the rules. One die usually carries several labels, or positions, and cuts all of them with each stroke.

• Base: The board that holds the rules. The standard base is plywood; an acrylic (Plexiglas) base is available on request. The rule channels are laser-cut into the base.
• Steel rule: The strip steel that forms the cutting line. Its height is given in mm and its thickness in points. When people say “label knives”, they usually mean the whole die, and sometimes just these strips.
• Ejection rubber: Sits on both sides of the cutting edge, lifts the material off the rule after the cut and stops the sheet from sticking to the die.
• Additional elements: Punches for holes, perforating rule for tear lines and, where needed, a second rule at a different height can sit in the same base.

Names vary from shop to shop, but most describe the same tool. Label die, label cutting die and steel rule label die all describe the rules set in their base. A sticker die is the same tool used for small, shaped self-adhesive work. A barcode label die carries the thin rule used for barcode and product labels. On roll-fed label presses, the die mounted in the flatbed unit is often simply called the flatbed die.

Because the die repeats exactly the same contour on every stroke, the edge of a die-cut label stays the same across thousands of labels. How label dies relate to carton and general cutting dies is explained in the complete cutting die guide.

Label cutting methods: flatbed, rotary and digital

There are three basic ways to cut labels, and the die decision follows from which one is used.

Flatbed die cutting

A steel rule die set in a flat base is pressed against a flat counter surface. This method runs on platen and clamshell presses, on cylinder presses for sheets, on automatic flatbed die cutters and in the flatbed unit of roll-fed label presses. In a roll-fed flatbed unit the web advances one step, stops, and the die comes down at that moment. A flatbed steel rule die is produced quickly from a drawing, a new shape costs relatively little in tooling, and the same die can serve repeat jobs for years.

Rotary die cutting

A cylindrical die, or a thin flexible plate wrapped around a magnetic cylinder, cuts while the web moves continuously. It belongs to very high-speed, continuous roll lines and is made with a completely different technique from a flat steel rule die. İkram Lazer does not make rotary dies, flexible dies, magnetic cylinder plates or rotary cutting blades; the method is mentioned here only to make the distinction clear.

Digital (dieless) cutting

A plotter knife or laser reads the contour from the file and cuts each label individually. No physical die is needed; it suits short trial runs of a few hundred labels, frequently changing designs and personalised labels. As quantities grow, cutting time per label becomes decisive. When the same shape repeats regularly in larger quantities, a steel rule die becomes the more efficient choice because it cuts every position at once.

Ask these questions before deciding: Will the label be reprinted with the same shape? How many sheets or metres of web does one job involve? Does the press have a flatbed die-cutting unit? Does the shape change often? For repeat work in medium and high quantities, the flatbed steel rule die is the most common way to cut labels. Choosing a method by press type is covered in which die your finishing job needs.

Kiss-cut, through-cut, perforation and holes

Not every line in a label die does the same job. Stating what each line must do is the first condition for building the die correctly.

Kiss-cut

The rule cuts the face stock and adhesive, touches the silicone liner and stops. The label stays on its carrier, the waste around it, known as the matrix, is stripped away, and the labels are lifted one by one by hand or machine. Most self-adhesive labels are cut this way. A kiss-cut succeeds when the liner is not cut and every label lifts equally easily from every position. The logic is explained in rule height and kiss-cut logic.

Through-cut

The rule cuts every layer, liner included. Dividing a sheet into small sticker cards, labels that leave together with their liner and non-adhesive board labels are through-cut. In one die the label contour can be kiss-cut while the sheet or card edge is through-cut; the two lines are then built with rules of different heights.

Perforation and tear lines

A perforating rule alternates cut and uncut sections with its teeth. It is used for tear-off coupons, easy-separating label strips or a fold line on the back of the liner. Tooth spacing and cut length decide how easily the line tears; state what you expect in the order.

Holes and windows

A hang hole, a neck opening for a bottle or a window inside the label is marked as a separate cut within the contour. Small round holes use punches; larger or shaped openings use bent rule. Plan how the inner waste will leave the die from the start.

• Put kiss-cut, through-cut, perforation and hole lines on separate layers and in separate colours in the dieline file.
• Name each layer clearly in the file, for example “kiss-cut”, “through-cut”, “perforation”.
• For kiss-cut work, add a liner sample or the stock’s product code to the order.

Label rule dimensions: 8, 12 and 23.8 mm height and point thickness

Two dimensions define a label rule: height and thickness. Height is the overall distance from the base of the steel strip to its cutting edge and is given in mm. Thickness is the distance between the two broad faces of the strip and is given in points. The two are independent and are written on separate lines in an order.

Height: 8, 12 and 23.8 mm

We make label dies with 8, 12 and 23.8 mm rule heights. The height comes not from the label but from the die seat and shut height of the press the die is mounted on. In the market, 23.8 mm is mostly seen on platen, clamshell and cylinder sheet presses and automatic flatbed die cutters, while 8 and 12 mm are mostly seen in the flatbed units of roll-fed label presses. In Turkish workshops a 12 mm rule is called a “12’lik”; the number is the rule height, not the number of labels on a sheet.

Thickness: points

Points are the trade unit for rule thickness. The equivalents used in the market are: 2 pt = 0.71 mm, 3 pt = 1.07 mm, 4 pt = 1.42 mm. On the same scale, 1.5 pt is about 0.53 mm. Thin rules are common in label work, and 2 pt is frequent on sheet labels. A rule 12 mm high and 1.5 pt thick is called a barcode cutting rule; its thin body lets contours sit close together on narrow barcode labels. It is also available with a titanium-coated edge on request. The coating is meant to keep the edge sharp for longer; it is not offered as a life or tolerance guarantee.

Edge profile

The cutting edge of a rule comes ground at different angles and profiles. Thin paper labels and thick film labels may not give the same result with the same edge. The edge is chosen for the material, which is why the material name and thickness belong in the order.

If you are unsure, measure the rule height and base thickness of an older die that runs well on the press, or send the die itself. Where the two dimensions get confused is covered in point thickness and height on a cutting rule, and the 12 mm rule in detail in what is a barcode cutting rule.

Label die-cutting presses and fitting the die to the press

The same label size can need a different die on a different press. Die size, mounting and rule height are set by the press. We build label dies for these press types:

• Platen and clamshell presses: Classic die-cutting presses where the sheet is hand-fed and the die closes against a counter plate. Common for small and medium runs of sheet labels and stickers.
• Cylinder presses: Presses with a cylinder impression mechanism, used for sheet labels and board.
• Automatic sheet-fed flatbed die cutters: Presses with automatic sheet feeding for high-volume sheet label and carton work.
• The flatbed unit of roll-fed label presses: The web from the reel advances in steps and the flatbed die comes down at each step. Common for barcode and product labels.

Three measurements matter for fit. The first is die area: the outside size of the die must fit the die seat or mounting plate of the press. The second is mounting: the holes, slots or clamps that hold the die in the press. The third is shut height: base thickness, rule height and any make-ready plate together must suit the press closing setting.

For the flatbed unit of a roll-fed press, web width and feed step are added. Web width limits how many labels can sit side by side across the die. The feed step is how far the web advances per stroke and must match the lengthwise pitch of the label rows on the die. The largest die area in the press brochure is a useful starting point, but the most reliable source is the size of a die already running on the press.

Details for the flatbed units of roll-fed label presses are collected on the flatbed steel rule label dies page.

Die base: plywood and acrylic

The standard base for label dies is plywood. Its layered structure holds laser-cut channels accurately, grips the rule firmly and carries the rubber well. Dies for sheet presses are usually built on thicker boards, while dies for the flatbed units of roll-fed presses are built on thinner bases to suit the press.

On request, we set the same rules in an acrylic (Plexiglas) base. Some converters ask for an acrylic base to match the dies already in their shop or to see through the die. The choice follows the press mounting and the dies you already use.

• State the base material and thickness of the die currently running on your press.
• If the die is mounted with holes or bolts, send the hole positions with dimensions.
• If you want an acrylic base, put it on the first line of the order; base thickness and rule height are planned together.

How to prepare the label dieline

The label dieline is the vector drawing of the line the rule will cut; it is also called the cut line or cutting contour. The die is built from this drawing: İkram Lazer processes the approved dieline to a 0.05 mm drawing tolerance, so the accuracy of the die depends first of all on the accuracy of the drawing. Looking at the edge of a cut label shows whether the die left a clean, fibre-free and complete cut.

Preparing the file

• Vector and true size: Send the cut line as PDF, AI, EPS or DXF at 1:1 scale. A die cannot be made from a JPG or a screenshot; in that case a measured drawing is prepared first.
• Single, closed paths: Every contour should be one closed path. Overlapping double lines, open ends and broken segments end up as double rules or gaps in the die.
• Separate layer and colour: Keep the cut line apart from the artwork, in its own spot colour with a clear name. Kiss-cut, through-cut and perforation lines each belong on their own layer.
• Corner radius: For round-cornered labels, give the radius as a measurement. Very small inside radii and sharp inside corners approach the limit of how tightly the rule can be bent; choose the softest transition the design allows.

Artwork and cut line together

Background print is extended beyond the cut line; this bleed is 1–2 mm on most label jobs. A small shift at the cut then leaves no white strip on the label edge. Text, barcodes and logos stay a safe distance inside the cut line; 1.5–2 mm is typical. A barcode’s quiet zone should not approach the cut line.

Matching a custom contour to the artwork is covered in preparing a cut line for a custom-shaped label, and aligning the print PDF with the dieline in aligning the artwork PDF with the dieline.

Sheet and roll layout: positions, gaps and waste

How labels are arranged on the die decides both material yield and cut quality. Sheet labels and roll labels answer different questions here.

Layout on a sheet label die

The sheet size sets the number and arrangement of positions. A gripper margin is left on the feed edge, and the other edges need room for cutting and stripping. Most jobs leave a 2–3 mm gap between labels so the matrix, the waste between labels, can be stripped in one piece. Rectangular labels can also be laid out with no gap on a shared rule; waste falls, but each edge then cuts two neighbouring labels at once.

Layout on a die for the flatbed unit of a roll-fed press

On a flatbed die for a roll-fed press, labels are arranged in rows along the web and in lanes across it. The number of lanes, the gap between lanes, the gap between rows and the feed step per stroke are planned together. Leave enough margin at the web edges so the matrix does not break while it is stripped. The label’s orientation on the roll, meaning which edge leaves the labelling machine first, also affects the layout.

Waste is best reduced at the design stage. A change of a few millimetres in label size can fit another row onto the sheet. Layout and waste calculation are covered step by step in planning layout and waste in a sheet-fed label die.

Choosing the rule by material: paper, thermal, PP, PET and more

When choosing a label rule, the construction of the material matters as much as its name. Two materials with the same name can come with different liners and adhesives. Sending the stock’s product code or data sheet with the order is the safest route.

• Coated and uncoated paper labels: The most common label stock. It cuts easily and gives a clean edge as long as the liner is protected. A thick varnish or laminate adds to the total thickness.
• Thermal labels: Paper with a heat-sensitive coating; direct thermal labels are common for barcodes and shipping. Because the surface reacts to pressure and friction, rubber placement and pressure balance are set with extra care.
• PP (polypropylene) labels: White, clear or metallised. The film is flexible, so the edge must be sharp and the pressure even; otherwise the edge can crush or the cut can stay incomplete.
• PET labels: A stiff, durable film. It needs a sharp edge and shows a stronger tendency to crack in tight corners. Soft corner radii in the design help.
• Vinyl and speciality films: Used for outdoor and durable labels. Their thickness and flexibility vary, so rule and rubber are chosen for the material.
• Kraft and textured papers: Their fibrous structure can leave a fuzzy edge; the condition of the cutting edge matters more here.

The liner is part of the material too. Glassine liners are mostly around 50–60 microns; PET liners are thinner and commonly used in the 23–50 micron range. A thin, stiff PET liner narrows the window in which the rule must stop in a kiss-cut, so always state the liner type. The thickness and flow of the adhesive also set the risk of bleed at the cut edge.

Rule choice by material is covered in choosing a cutting rule for paper, thermal, PP and PET labels, and the effect of liner and adhesive on setup in liner, adhesive bleed and kiss-cut settings.

Ejection rubber, matrix stripping and clean release

The rubber on a label die is bonded on both sides of the cutting edge and stands slightly above the rule. When the die closes, the rubber compresses; when it opens, it pushes the material off the rule. Without rubber, material catches on the rule, the sheet is hard to release and label edges can tear.

• Hardness and height: Rubber hardness and how far it stands above the rule are chosen for the material. On thin labels, rubber that is harder than needed can crush the liner and make the kiss-cut harder to control.
• Placement: Rubber too close to the rule pushes material sideways during the cut; too far away, it does not release the material. With tightly spaced labels, rubber width is planned carefully.
• Matrix stripping: After a kiss-cut, the waste between labels, the matrix, is stripped off the liner. A narrow or interrupted matrix breaks while being stripped, so gaps, corner radii and stripping direction are considered together at the layout stage.

Clean stripping needs the cut to be complete at every position. A single point of uncut face stock ties the matrix to the label and pulls the label off the liner. Rubber selection is covered in choosing ejection rubber, and when to renew it in signs that ejection rubber needs replacement.

First sheets on the press: how to check the cut

After a new label die is mounted, the first sheets or the first metres of web are where the die and the setup are confirmed. Take samples from the edges and the middle, not from one spot only.

• Lift one label from every position: do they all lift equally easily? Mark any position that resists.
• Hold the liner up to the light: can the cut line be seen from the back? If so, the cut is too deep.
• Fold the liner after the labels are removed: does it break along the cut line? If so, the liner has been damaged.
• Check the corners: is the cut complete at round corners and points?
• Compare print and cut: is the cut aligned with the printed contour? Is any shift the same across the sheet, or local to one area?

Rather than raising pressure again and again, find which position and which area has the problem. An even depth problem across the whole sheet points to press setup; a problem that repeats in one area points to the die or the make-ready plate. To confirm kiss-cut depth step by step, use how to test kiss-cut depth. Record the approved setup, material and die number in the job file so the next run starts from the same point.

Common label cutting faults and first checks

The liner is being cut

If the rule goes into the liner, check the press closing setting and the make-ready plate first. If the problem covers the whole sheet, the setting is too deep; if it is confined to one area, there may be a high spot or an uneven plate there. Check whether the liner type has changed; switching to a thin PET liner makes the same setting too deep. More in how to prevent liner cutting.

The label is not fully cut or the corner will not lift

An incomplete cut can come from a worn edge, rubber that is too hard or too little pressure. If only the corners stay uncut, check the corner radius, the rule bend and the rubber placement at that point. Mark first which position the incomplete cut is in.

Adhesive bleeds and sticks to the rule

If adhesive oozes from the cut edge, labels stick to the die, the matrix breaks and the edge gets dirty. Adhesive thickness, room temperature, pressure and cutting speed all play a part. Cleaning the rule regularly and reviewing rubber placement are the first steps. More in how to prevent adhesive bleed.

The fault is always at the same position

If the problem repeats at the same position on every sheet, look at that area of the die: cutting edge, channel seating, rubber and make-ready. A problem that moves from sheet to sheet usually comes from feeding, material or the press. The method: diagnosing position-specific cutting faults.

The cut shifts against the print

If all labels shift in the same direction, check the sheet reference, feeding or, on a roll-fed press, the feed step. If the shift grows towards one end of the sheet, the print size and die size may differ. First confirm that the artwork and the die come from the same revision. More in print-to-cut misregister: die or machine?.

Fuzzy or dusty edges

Fibres and dust on the edge point to a worn cutting edge or an edge profile that does not suit the material. Kraft and textured papers show this sooner. For a general list of label and carton faults, see the die-cutting defects checklist.

Label die life, maintenance and storage

The life of a label die depends on how it is used, so no impression count is given. Material, pressure, press setup and maintenance decide how long a die lasts. Film labels, abrasive coatings and heavily adhesive stocks can wear the cutting edge sooner. Stating the expected run length in the order lets the die be planned for it.

• Cleaning: Remove adhesive and paper dust from the cutting edge at the end of each job. Built-up adhesive spoils the cut on the next run.
• Storage: Store the die flat, dry and with no load on top. A plywood base can move in a damp room.
• Labelling: Write the job name, customer code and file revision on each die. Finding the right die for a reorder becomes easy.
• Rubber and rule checks: Before a repeat job, check for hardened, torn or lifted rubber and rules with a rolled edge.

Maintenance and reuse are covered in die maintenance, storage and reuse, and the repair-or-remake decision in repair or remake a cutting die. For rule and rubber renewal on your existing dies, see cutting die repair and refurbishment.

What determines the cost of a label cutting die?

The cost of a label die comes from the die itself, not from the number of labels printed. When two quotations for the same label differ, compare whether they cover the same scope:

• Total rule length: More positions and longer contours mean more steel rule.
• Shape complexity: Tight corners, many bends and nested contours add work.
• Die size and base: A large sheet die and a small die for a roll-fed flatbed unit need different bases; an acrylic base is a separate item.
• Additional lines: Holes, perforation, a second through-cut height and windows add cost.
• Rule choice: Point size, edge profile and a titanium coating request.
• Rubbering and lead time: Amount of rubber and delivery urgency.

Once made, a die is used again on repeat jobs for the same label, so its cost is judged against the total run rather than a single job. Each item is explained in what determines the cost of a label cutting die.

What to send when ordering a label die

A complete order lets the die be made right the first time and shortens the quotation. Send the following in one message:

• Dieline file (PDF, AI, EPS or DXF), or a label sample or existing die to measure from
• Label size, corner radius and number of positions on the sheet or web
• Cut type: kiss-cut, through-cut, perforation, holes
• Material: face stock, adhesive and liner type; the product code if possible
• Press type and model, die area and mounting
• Rule height (8, 12 or 23.8 mm) and point size; if unknown, the measurements of an older die
• Base: plywood or acrylic
• Sheet size or web width, number of lanes, gaps and feed step
• Expected run length, repeat work and the delivery date you need

At İkram Lazer, standard-size label dies are produced within 4–18 hours; the exact lead time is confirmed once the file and material details are seen. How converters and printers can prepare an order together is listed in a cutting die order guide for label converters.

İkram Lazer’s label die scope

İkram Lazer makes flatbed steel rule label dies for label printers and converters. We build them for platen, clamshell and cylinder presses, automatic sheet-fed flatbed die cutters and the flatbed die-cutting units of roll-fed label presses. Rule heights are 8, 12 or 23.8 mm; the base is plywood, or acrylic on request.

• Dies for sheet labels, stickers, custom-shape labels and barcode labels
• Kiss-cut, through-cut, perforation and holes in the same die
• New dies measured from an existing die or a label sample
• Rule and rubber renewal on older dies

We do not make rotary dies, flexible dies, magnetic cylinder plates or rotary cutting blades. We do not print labels or sell label presses or finished labels. These limits are stated plainly so that the die you order fits your press and your job.

You can request a quotation for sheet labels and stickers on the label cutting dies page, for the flatbed unit of a roll-fed press on the flatbed label dies page, and for a copy of a label you already have on the sample to cutting die page. During working hours, quotation replies take 12 minutes on average.

Frequently asked questions