How Do I Design a Part for Die Cutting? | Design Guide
Learn how to design parts for die cutting, including material selection, thickness, tolerances, holes, corners, geometry, CAD files and production quantities.
Southwest-Diecutting Engineering Team
9/16/202610 min read
How Do I Design a Part for Die Cutting?
Designing a part for die cutting is different from designing a part for machining, 3D printing, injection molding, or laser cutting. A die-cut part can often be produced quickly and economically, but the material, geometry, tolerances, holes, corners, and overall layout all affect how well the part will die cut.
The good news is that most parts do not need to be redesigned specifically for die cutting. With a few considerations during the design stage, you can often make a part easier to manufacture, reduce tooling costs, improve consistency, and avoid problems during production.
Whether you are designing a gasket, seal, insulator, pad, washer, label, filter, foam component, or other flexible sheet component, this guide explains the most important things to consider when designing a part for die cutting.
[IMAGE PLACEHOLDER – Example of a die-cut part with dimensions and features identified]
1. Start With the Material
The material is one of the first things to consider when designing a die-cut part.
Die cutting is commonly used for materials such as:
Rubber
Silicone
EPDM
Neoprene
Buna-N
Viton® / FKM
Polyurethane
Foam
EVA
Cork
Felt
Plastic films
Adhesive-backed materials
Fabrics
Paper and sheet materials
Gasket materials
Magnetic materials
Different materials behave differently during cutting. A soft foam, for example, may compress during the cutting process, while a firm plastic film may behave very differently under the same conditions.
Material thickness, hardness, density, flexibility, compression characteristics, and surface construction can all affect the finished part.
If you are not sure which material is appropriate for your application, start with our Materials Guide.
2. Consider the Material Thickness
Thickness is one of the most important dimensions when designing a die-cut part.
A die must be designed to cut through the material cleanly and consistently. As material thickness increases, the cutting process can become more demanding, particularly with intricate shapes or small internal features.
When specifying your material, include the nominal thickness and any acceptable thickness tolerance if it is important to your application.
For example:
Material: EPDM
Nominal thickness: 0.062 inch
Thickness tolerance: As specified by material manufacturer
If the material specification is flexible, let your die cutter know. There may be several materials or thicknesses that will meet the functional requirements of your part while producing a more economical result.
3. Avoid Extremely Small Features When Possible
Small holes, narrow slots, thin webs, and tiny internal features can make a die-cut part more difficult to manufacture.
The smaller the feature relative to the material thickness, the more important the relationship between the material and the die design becomes.
For example, a very small hole through a relatively thick rubber material may be substantially more difficult to produce than the same hole in a thin film.
That does not mean small features cannot be die cut. It simply means they should be considered early in the design process.
If a small feature is necessary, identify it on your drawing and discuss it with your die cutter before finalizing the design.
4. Pay Attention to Hole-to-Edge Distance
The distance between an internal hole and the outside edge of the part can be important.
If a hole is placed very close to the edge, the narrow section of material between the hole and outside perimeter may be difficult to maintain during cutting, handling, stripping, or production.
A wider web between features generally provides a more robust part.
There is no single hole-to-edge dimension that works for every application. The appropriate minimum depends on factors such as:
Material
Material thickness
Material hardness
Hole size
Part geometry
Required tolerance
Production volume
Die construction
If your design contains closely spaced holes or narrow webs, send the drawing to your die cutter for review before committing to tooling.
5. Avoid Unnecessarily Tight Tolerances
One of the easiest ways to increase manufacturing difficulty and cost is to specify tighter tolerances than the application actually requires.
Before putting a very tight tolerance on your drawing, ask:
Does this dimension really need to be that precise for the part to work?
A gasket, seal, insulation pad, or foam component may perform perfectly well with a tolerance that is less demanding than a precision machined component.
Tolerances should be based on function rather than simply making every dimension as precise as possible.
Tighter tolerances may require additional process controls, inspection, tooling considerations, or material selection.
For more information, see our Die Cutting Services page or contact us to discuss your specific tolerances.
6. Think About Corners and Radii
Sharp inside corners can be more difficult to produce than rounded corners, depending on the material, thickness, and geometry.
If a sharp corner is required for the function of the part, it may still be possible. But if the radius is not functionally important, adding a small radius can sometimes make the part easier to manufacture.
For example, consider whether a corner really needs to be:
0.000-inch radius
or whether:
0.010-inch radius
would perform exactly the same function.
The answer depends on the application, but eliminating unnecessary sharp corners can sometimes make tooling and production easier.
7. Keep Narrow Sections in Mind
Very narrow sections of rubber, foam, gasket material, or other flexible materials may be difficult to maintain during production.
A narrow section can:
Tear during stripping
Stretch or deform
Remain attached to surrounding scrap
Make automated handling more difficult
Affect dimensional consistency
Again, there is no universal minimum width. The acceptable geometry depends on the material and thickness.
If your design contains long, narrow sections or delicate webs, it is worth having the geometry reviewed before the die is made.
8. Consider How the Finished Part Will Be Used
A part that is easy to die cut is not necessarily a part that will perform properly in the final application.
Consider the actual function of the component.
For example:
Gaskets
Consider:
Sealing surface
Compression
Temperature
Chemical exposure
Bolt-hole locations
Material thickness
Required compression
Electrical Insulation
Consider:
Dielectric requirements
Thickness
Operating temperature
Adhesive requirements
Creepage and clearance
Foam Components
Consider:
Compression
Density
Recovery
Adhesive
Environmental exposure
Adhesive-Backed Parts
Consider:
Adhesive type
Liner construction
Application surface
Kiss cutting versus through cutting
How the part will be removed from the liner
The best die-cut design considers both how the part is manufactured and how the part will function.
9. Decide Whether You Need Kiss Cutting or Through Cutting
Not every die-cut part needs to be completely separated from its material.
With adhesive-backed materials, labels, tapes, films, and similar products, kiss cutting can cut through the face material while leaving the liner intact.
This allows individual parts to remain attached to the liner until they are needed.
Through cutting, on the other hand, separates the part completely from the sheet or material.
The correct process depends on how the part will be supplied and installed.
10. Think About Adhesive and Liner Construction
If your part uses adhesive, include the complete material construction in the drawing or RFQ.
For example:
Face material: Polycarbonate
Thickness: 0.010 inch
Adhesive: Pressure-sensitive adhesive
Liner: Release liner
A die-cut adhesive component is not simply a single layer of material. The adhesive, liner, and release characteristics can affect how the part is converted and supplied.
If the part will be supplied on a liner, specify whether you need individual pieces, sheets, rolls, or another configuration.
11. Design the Part at the Actual Finished Size
Your drawing should clearly identify the finished part dimensions.
Avoid relying on descriptions such as:
“Cut approximately to this shape.”
Instead, provide dimensions and tolerances for the features that actually matter.
A good drawing should identify:
Overall length
Overall width
Hole diameters
Slot dimensions
Radii
Material thickness
Critical feature locations
Required tolerances
Material specification
Adhesive requirements
Quantity
The more clearly the functional requirements are defined, the easier it is for your die cutter to quote and manufacture the part.
12. Provide a Good CAD File When Possible
If you have a CAD file, provide it with your drawing.
Common file formats used for manufacturing include:
DXF
DWG
STEP
PDF
AI
EPS
SVG
The exact format needed can depend on the part and the tooling process.
A vector drawing is particularly useful because it provides the actual geometry needed to create tooling.
If you only have a PDF, sketch, photograph, or physical sample, don't assume the part cannot be made.
A good die cutter can often work from the information available and determine what additional information is needed.
13. Don't Overcomplicate the Design
Sometimes engineers add features to a design because they are possible to manufacture using another process.
With die cutting, simpler geometry is generally easier to manufacture.
Before adding a small notch, narrow slot, unusual radius, or other feature, ask whether it is actually necessary.
For every feature, consider:
Does this feature serve a functional purpose?
If not, eliminating it may:
Simplify the tooling
Improve production reliability
Reduce scrap
Make inspection easier
Reduce cost
This is particularly important when designing a high-volume part where a small manufacturing improvement can have a significant effect over thousands or millions of pieces.
14. Consider the Quantity You Need
The number of parts you need can influence the most appropriate die-cutting process.
For a small prototype quantity, the tooling and setup considerations may be different from a production requirement of hundreds of thousands or millions of pieces.
If you are still developing the design, tell your die cutter that the part is a prototype.
If the design is finalized and you expect ongoing production, provide your estimated annual or lifetime quantity.
This information helps the die cutter determine the appropriate tooling and production method.
You can also learn more about the economics of die cutting on our Pricing page.
15. Design With the Manufacturing Process in Mind
One of the biggest advantages of involving your die cutter early is that you may be able to identify potential problems before tooling is manufactured.
For example, a drawing review may identify:
A hole that is unnecessarily small
A web that is too narrow
A tolerance that is tighter than necessary
A material thickness that could be changed
A feature that could be eliminated
A better material option
A different die-cutting method
An opportunity to reduce material waste
A five-minute discussion before tooling is ordered can sometimes prevent much more expensive changes later.
Die Cutting vs. Laser Cutting
Die cutting isn't always the best manufacturing process for every geometry.
Laser cutting can be useful for prototypes, complex shapes, changing designs, and lower-volume work where dedicated tooling may not make economic sense.
Die cutting is often attractive for repeat production where consistent shapes, production speed, and cost per part are important.
You can compare the two processes in our guide:
Laser Cutting vs. Die Cutting: Which Is Right for Your Part?
What Materials Work Best for Die Cutting?
Die cutting is commonly used for flexible and semi-flexible sheet materials, including rubber, foam, gasket materials, plastics, films, fabrics, felt, cork, adhesives, and many other materials.
However, the fact that a material can technically be cut does not necessarily mean it is the right material for your application.
Material selection should consider:
Temperature
Chemicals
Compression
Flexibility
Hardness
Electrical properties
Environmental exposure
Adhesion
Required thickness
Expected service life
See our Suitable Materials page for more information.
What Information Should I Include When Requesting a Die-Cutting Quote?
When you are ready to request a quote, providing the following information can make the quoting process much easier:
1. Part drawing
Include dimensions, tolerances, material, and critical features.
2. CAD file
Provide a DXF, DWG, or other available digital file when possible.
3. Material
Specify the exact material and manufacturer/part number if known.
4. Thickness
Include nominal thickness and any required tolerance.
5. Quantity
Provide prototype quantity, initial order quantity, and estimated annual usage if available.
6. Adhesive requirements
Identify adhesive type, thickness, liner, and whether the adhesive needs to be kiss cut.
7. Application
Explain what the part does and the environment in which it will be used.
8. Critical requirements
Identify any dimensions, surfaces, holes, or features that are especially important.
You can provide this information through our Die Cutting Quotation page.
What If I Don't Have a CAD Drawing?
Don't let the lack of a CAD file stop you from asking for a quote.
Depending on the part, a die cutter may be able to work from:
A PDF drawing
A physical sample
A sketch
A photograph
An existing part
An older drawing
A DXF or other CAD file
If you have a sample but no drawing, provide as much information as possible about the material, thickness, quantity, and application.
The more information you can provide, the easier it will be to determine what is required to reproduce the part.
Can a Die-Cut Part Have Complex Shapes?
Yes.
Die cutting is capable of producing many complex two-dimensional shapes, including:
Irregular perimeters
Multiple holes
Slots
Cutouts
Tabs
Notches
Gasket profiles
Adhesive-backed shapes
Repeating patterns
The important consideration is not simply whether the shape is complex, but whether the combination of geometry, material, thickness, tolerances, and quantity is appropriate for the die-cutting process.
10 Quick Design Rules for Die-Cut Parts
Before sending your drawing for quotation, check these ten items:
Specify the correct material.
Specify material thickness.
Identify critical dimensions and tolerances.
Avoid unnecessarily small holes and narrow webs.
Consider radiusing sharp corners where possible.
Identify adhesive and liner construction.
Specify kiss cutting or through cutting when applicable.
Provide a CAD file or other usable drawing.
Provide expected quantities.
Tell your die cutter how the part will be used.
Following these guidelines can make quoting and production much smoother.
Frequently Asked Questions About Designing Parts for Die Cutting
What is the best material for a die-cut part?
There is no single best material. The correct material depends on the application's temperature, chemical exposure, compression, flexibility, electrical requirements, environment, and other functional requirements.
How thick can a material be die cut?
The practical thickness range depends on the material, its properties, the part geometry, and the cutting process. Thick materials with small holes or intricate features may require different tooling considerations than simple shapes.
How small can a hole be in a die-cut part?
There is no universal minimum hole size. The practical limit depends on material type, material thickness, hole geometry, tolerances, and tooling method.
If your part has very small holes, include them in your drawing and discuss them with your die cutter before tooling is manufactured.
Can rubber be die cut?
Yes. Many rubber materials are commonly die cut, including EPDM, neoprene, Buna-N, silicone, Viton®/FKM, and other rubber compounds.
Can foam be die cut?
Yes. Many foam materials can be die cut, including EVA, polyurethane, polyethylene, neoprene foam, and other flexible foam materials. Foam density, thickness, compression, and cell structure can affect the cutting process.
Should I use die cutting or laser cutting?
It depends on the application.
Laser cutting can be useful for prototypes, complex geometries, and situations where designs change frequently. Die cutting can be advantageous for repeat production and higher-volume applications.
The material itself is also an important consideration.
How much tolerance can die cutting hold?
The achievable tolerance depends on the material, thickness, geometry, tooling, production method, and quantity. Instead of automatically specifying extremely tight tolerances, identify which dimensions are functionally critical.
Can you die cut a part from a sample?
In many cases, yes. A physical sample can provide useful information when a CAD drawing is not available. The sample may need to be measured or reverse-engineered before tooling can be created.
Does the part need to be designed specifically for die cutting?
Not necessarily. Many parts designed for other manufacturing processes can be die cut. However, reviewing the geometry for die cutting before tooling is made can identify opportunities to simplify the design, improve manufacturability, and potentially reduce cost.
Need Help Designing a Part for Die Cutting?
If you're an engineer designing a new component, don't wait until the drawing is finalized to talk to a die cutter.
A quick review of your material, geometry, tolerances, quantity, and application can help identify potential manufacturing issues before tooling is ordered.
Mag-Knight Die Cutting works with customers on custom die-cut components, gaskets, seals, insulation, foam parts, adhesive-backed components, and other precision sheet-material applications.
If you already have a drawing, CAD file, or sample, send it to us for review.
You can also learn more about our Die Cutting Services and Suitable Materials.
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