Die-cutting is a great way of making cost-effective packaging and protection for your product. It is best used for mass production due to the initial outlay for the tooling.
Benefits of Die Cutting
For simple shapes or where the whole cut can go through the foam, die-cutting can be very cost-effective in large volumes. However, Manufacturers usually use Lower-grade foam in the die-cut process. This is due to the manufacturing industry using this technique in one-way packaging – as a supplier will not receive it again.
Companies use it largely for packing out cardboard boxes to provide protection to the products but at a minimal cost. For example, when buying a new PC, the foam inside the box will usually be large to provide good protection but also of a low grade to make it cost-effective.
A manufacturer might use a higher grade of foam in the die-cut process of a presentation style box. This makes the product inside more appealing to the customer.
The process does require new tooling for each design. This can be expensive for low volumes or if not being used often. CNC-routing is an alternative solution for small volumes of production.