Post-Offset Printing Processes That Use Dies

By: Rachelle Lim
Submitted: 2008-07-05 22:39:16
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Dies are widely used materials in different industries, from steel manufacturing to offset printing.  These tools function to cut or form materials in order to add to a product’s aesthetic value or to complete product components. 

In the field of printing, processes that involve dies are primarily done to enhance the appearance of print products such as business cards and postcards, or to make them functional, like pocket folders.  These processes are die cutting, embossing and debossing.

Although they all require dies, embossing and debossing differ from die cutting in that nothing is removed during these procedures. 

How dies are formed and used

The key to a successful die use is the precision involved in preparing the dies.  There are some projects that require intricate details so the same are expected from the dies. 

Dies for cutting are made by bending metal pieces with sharp edges to facilitate trimming of undesired paper sections.  These dies are mounted onto an object that will keep it in a fixed position during cutting to prevent it from moving during trimming. 

For embossing and debossing, on the other hand, two metal dies which serve as molds are used, none of which have sharp edges since the whole paper has to remain intact.  The objective in these processes is to create a raised or submerged impression using a female die and a counter die (male), along with the application of heat and pressure.

The die processes

1.    Die cutting

This procedure is done to trim away edges and certain areas of the paper.  For more impressing printouts or marketing materials, this is used to modify the shape of print products, functioning in the same mechanism as a cookie cutter.  For instance, instead of having a plain rectangular birthday postcard, you can ask your printer to cut it following the outline of a cake with candles. 

2.    Embossing

With this die-assisted effect, the images or print components are raised.  The male die (raised mold) is positioned at the bottom.  The female die (deep mold) is placed on top, facing downward in such a way that when it is lowered, the male and female die will lock together.  The paper to be embossed is sandwiched between the dies, and then heat and pressure are applied.

Embossing can be done on an entire image or on the texts, or on selected parts of the print only.  There are times when embossing is done without ink and this is called blind embossing.  The text or image becomes apparent with proper lighting, and the shadows casted help make the embossed impression appear.

3.    Debossing

Debossing follows the same principle as embossing but the positions of the male and female die are reversed to create a sunken image. 


Such processes easily add character and appeal to the print product.  This is particularly helpful if you are targeting high audience impact, as in the case of marketing campaigns.  Creativity in the design and accuracy in execution can contribute to the success of your marketing approach.

However, do note that die cutting, embossing and debossing can make your printing cost increase quite considerably.  If you really want to have these procedures done, try to scout for a good deal so you would not have to spend so much, apart from your offset printing costs.

Article source: Expert Articles