Die Cutting vs Laser Cutting: What is the Difference?

When it comes to cutting materials in the desired shape and design, everyone would love to get perfect and impeccable results. That is why users research the best machine they can use.

Die cutting and laser cutting are two different technologies that are used for cutting. They have different applications, limitations, advantages, and disadvantages. Before selecting any of the machines, it is a must to understand what these machines are and how they work.

This article is a complete guide on Die Cutting vs Laser Cutting. We will discuss both in detail and compare their technology, features, and other aspects. It will help you select the right machine for your needs.

What is Die Cutting? How Does It Work? 

Die Cutting is a simple process of cutting materials in the desired shape and design by using a sharp-edged die. The die has an intricate pattern or design, and its edges are just like blades. It is placed over the material, and a uniform pressure is applied using the die-cutting machine. The pattern is cut due to the sharp edges of the die, and you get the desired shape of the material with perfection. 

It is a very simple technique that has been in use for centuries. It is usually used for cutting paper and cardstock, but you can also find die cutters cutting leather, vinyl, and cardboard. You can use any type of die you want and cut the material as you like. Due to the uniform die, you always get uniform cuts.

Image Credit: Freepik

Types of Die Cutting Machines

We can broadly classify die-cutting machines into two types: Manual Die Cutting Machines and Digital Die Cutting Machines.

Manual Die Cutting Machine

A manual die cutting machine has a lever or crank, which is rotated to move the material and exert pressure on the mold.

Image Credit: sizzix.com

Firstly, the die is placed over the material, let's say cardstock. Now, one cutting plate is placed underneath the material, and another cutting plate is placed at the top. The plates ensure the die does not cut multiple layers and a uniform pressure is exerted on the whole die.

The plates with the material and die are placed on the die cutting machine. After that, the crank is rotated. It moves the plate forward and exerts pressure on the die. You can rotate the crank in the opposite direction to get the plate back to its place.

Finally, the plates are removed, and you get a perfectly cut shape of cardstock. It is quite simple, but you need to exert some force to move the crank. You can also find the electronic version of a manual die-cutting machine. The only difference is that there is no lever on it, but the motor moves the plates forward and backward.

Digital Die Cutting Machine

A digital die cutting machine is much different than a manual machine. It is more versatile, precise, and quick. Instead of the traditional die, it uses a blade cutting tool, which moves according to the program or file provided.

Image Credit: silhouetteamerica.com

The machine comes along with software. You need to import digital files to it and then cut the desired shape. You can find digital files online or make yourself on any designing software. 

It is a much better option than a manual die cutting machine because you are not limited to the number of dies you have. You can make almost anything without limitations. All you need to do is change the blade once it wears out.

Advantages of Die Cutting

Identical Results

Due to the die, the die cutting process always produces identical results. It does not matter how many pieces you need; you will get exceptional results every time without hassle. This is quite difficult to achieve with other methods. 

Clean Cutting

Die cutting can produce precise and smooth cuts, as long as the die blades are well-maintained and sharp. Unlike other methods that may leave rough or uneven edges, die cutting ensures that the final product has a flawless and professional appearance. This is especially important for products that require high standards of accuracy and aesthetics, such as stickers, labels, cards, or packaging.

Exceptional Speed

Die cutting can produce the desired shape or pattern with just one press of the die. This process can take only a few seconds, depending on the size and complexity of the design. Even manual die cutting machines are relatively quick and easy to use, as they only need a simple crank to operate.

Affordable

Die cutting is an affordable option. Firstly, the upfront cost of the machine is reasonable, and almost everyone can invest in it. Secondly, it is a manual machine, so it does not need electricity. All you need is the die for cutting the pattern.

Limitations of Die Cutting

In manual die cutting, you are limited to the number of dies you have. For instance, if you have one die of floral design, you can only punch that design on the material. If you want any other design, you need to get the die. Thus, you must invest in die according to your requirements. A manual die cutting is suitable for a small-scale business only. It is fast, but you can only cut in small volumes. Die cutting machines can cut limited materials, such as paper and cardstock. Only a few machines can cut leather, thick cardboard, and vinyl. Moreover, you cannot cut thick materials, and if you try to do so, the die blades will wear off quickly.

Die cutting machines have some limitations depending on the type of machine and the material used. Some possible limitations are:

• Material types and thickness:  Die cutting machines can cut limited materials, such as paper and cardstock. Only a few machines can cut leather, thick cardboard, and vinyl. Moreover, die cutting machines may not be able to cut through very thick or heavy materials, such as metal or wood. These materials may require more pressure or a different cutting method.
• Material shape: Die cutting machines may not be able to cut materials that are not in a roll or sheet form, such as irregular or 3D objects. These materials may not fit into the machine or feed through it smoothly
• Cutting precision: Die cutting machines may not be able to cut very intricate or detailed shapes, especially with manual machines that use steel dies. These shapes may require a higher level of accuracy or a different cutting method, such as laser cutting

Common Applications of Die Cutting 


Die cutting has many applications in various industries and products. Some examples of applications are:

Packaging

With die cutting, custom shapes and sizes of cardboard, carton, foam, plastic, or other materials can be created for different packaging products. These products include mailers, containers, stickers, cushions, and more.

Clothing

Die cutting can produce patterns and designs for clothing items from materials such as fabric, leather, felt, cotton, or vinyl. Tops, bottoms, coats, and more can be made with die cutting.

DIY Projects

Die cutting can also be used for DIY projects. Die cutting can create vinyl decals that can be applied to wine glasses or walls for a custom look, or iron-on vinyl designs that can be transferred to T-shirts for a personalized style. Die cutting can also create paper shapes that can be used to embellish greeting cards or scrapbook pages with different themes, such as flowers, hearts, stars, titles, frames, or accents. Die cutting is a great way to add creativity and variety to your projects.

What is Laser Cutting? How Does It Work? 

Laser cutting uses powerful laser beams to cut a wide range of materials in no time. The beams come out from a laser source, which is housed in the laser module. The laser beams are directed in a specific direction through mirrors and lenses to make a focal point. The laser module is controlled through software and moves according to the design file. With that being said, you can cut almost any type of design with perfection. All you need to do is upload the laser cut design to the software, and the laser machine will do the rest. 

Laser beams are quite powerful, and they burn or evaporate the material they come in contact with. They are compatible with cutting solid wood, plywood, acrylic, plastic, fabric, rubber, paper, cardstock, leather, etc.

You can cut thicker materials, even wood, up to 20mm in only one pass, depending on the power of the laser. Besides, they cut materials at an exceptional speed, which can reach up to 400mm/sec or even more. The best part about these machines is that you can not only cut the material, but you can also engrave it. You can control the power and speed and get the desired results on the material.

Types of Laser Cutting Machine

All types of laser machines use laser beams to cut materials and are controlled through software. They are classified according to the laser beams they produce. On that basis, you can find Diode Laser Cutters, CO2 Laser Cutters, and Fiber Laser Cutters as the most commonly used laser cutting machines on the market.

Diode Laser Cutters

A diode laser uses a power diode to generate laser beams. It is the most affordable type of laser cutting machine available on the market. These lasers produce laser beams in the range of 450nm, which is excellent for cutting wood, acrylic, fabric, cardstock, and some other non-metal materials. They are also ideal for engraving and are compatible with wood, ceramic, acrylic, fabric, glass, and some metals.

You can easily find 5W to 15W optical power in diode lasers on the market, but xTool offers up to 40W for cutting materials like butter. If you want an affordable desktop laser machine for hobby and small business, it could be an excellent option.

CO2 Laser Cutters

These laser machines use a CO2 tube to generate laser beams. The beams are exceptionally powerful and cut materials like a pie. The wavelength of a CO2 laser is around 10,600 nm, which is suitable for cutting a wide range of non-metals, including wood, acrylic, rubber, leather, paper, and fabric. These can also engrave on the material and produce excellent marks.

These lasers are a bit costly compared to a diode laser, but they are more powerful. They cut thicker materials in less time because their optical power is much more than a diode laser. The commonly used desktop CO2 lasers have a power of 30-40W, and you can easily find lasers having power in several thousand watts.