About Dies

Definition of a Die

A die is an assembly consisting of metal perforating or cutting blades called "rules", a wooden base to hold the rules and rubber insets to protect the rules when the die is secured in a letter press. Dies are reuseable.

Once mounted in the press, the die impacts the paper sheets and creates the specified impression, which can include perforations, scores, cuts, and punches (as in a hole), or any combination thereof.

Examples of some of our products include, door hangers, prayer cards, Chinese auction cards, telephone tear-off tabs and bingo pop-out sheets.

If you can imagine it, a die can be made for it!

When is a Die Necessary?

A high speed perforating machine with perforating wheels is suitable for most jobs requiring perforations that go from one edge of a sheet of paper to the other; however, if the perforations, scores or cuts do not, or, if curvilinear perforations are required, a die is necessary.

How a Die is made

In a nutshell:

The basic steps of creating a die are:

1) transferring your idea into a CAD software format (i.e.,Computer Aided Design software) and then transforming it onto a die board using a computerized laser cutting machine,

2) sizing and inserting the appropriate perforating, scoring, punching or cutting "rules" into the die board and

3) gluing protective rubber along the edges of the die rules to minimize damage.

laser cutting  

At left is a laser cutting machine that burns your design into the die board, which is 3/4" laminated wood. The cuts go through the entire board and the appropriate perforating, scoring and/or cutting rules are inserted all the way through as well.

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perforating rule  

At left is a perforating rule. This particular rule is a 32 TPI (teeth per inch) perforating rule, the beginning TPI ration often considered "micro perforation". Rules are also available for scoring, cutting and punching (as in holes) in myriad thicknesses, TPI and formats.

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bending machine  

After the appropriate perforating, cutting, scoring or punching rules have been selected for the job, they are bent and/or cut to fit the laser slots in the die board. At left is a rule bending machine where a rule is being configured.

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rules in board  

Once the rules have been cut and shaped to size, they are firmly inserted through the entire thickness of the die boards.This is a top view of the rules prior to installation of the protective rubber strips.

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impact side  

Shown here is the top - or impact - side of a die to make "memorial fans". The black pieces are foam to protect the rules of the die under repeated use.

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reverse side  

Shown here is the reverse side, or bottom, of the "memorial fan" die shown above. Note how the metal rules go through the entire die board to assure uniformity and strength. The small sections where there is no rule allows for "notches" or areas that are not cut.

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bingo die  

The die at left is the one we use for our pop-out bingo cards. When placed over our pop-out bingo boards, players can simply press down on the cut-out instead of placing markers.

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bingo die reverse  

Here is the bottom side of the pop-out bingo die. The "U" sections are cuts allowing for easy pop-out and push out.

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complex die  

Photo at left depicts a more complex die incorporating perforations, circles and punches. If you can think it, it can be done.

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How Much does a Die Cost?

The cost of a die depends on its complexity and the linear amount of rule necessary. Custom dies are made to order and for your exclusive use only.

When requesting a quote, please be sure to have a rough drawing or schematic of the format you want, along with the size and type of paper you require.

Call 800-364-1509 for your quote today!