Printed products of any shape thanks to cut-outs

Have you ever thought about how printed products of unusual and irregular shapes are made? It is a result of a method called cut-out. Using this method, products of various shapes can be made. It is also possible to cut into the material various letters and patterns. You will learn about the method, its drawbacks and how to choose the right method.

The last steps

Cut-out is one of the finishing operations in the production of printed products. First, paper is pressed, varnished or processed in another way and the required shape is cut out. A pre-cut out and cut out process must be impeccable and faultless work, otherwise the entire process must be done again, which results in a price increase.

Almost each printing company offers cut-outs. Various types of cut out methods can be used:

• Automatic cut-out line – the whole printing process is a seamless operation. Can be equipped with additional functions which provide relief stamping, application of holograms and gold plating
• Semi-automatic cut-out line – in form of plate press, most frequently up to format B3 (50×35.3 cm, 19.68in x 13.89in)
• Cut-out tapes – are added to the press, so the cut out is carried out during the printing process.

Cut-outs can be used for door labels, flyer holders, brochures, etc. Cut-outs are inevitable for various packages for food, pharmaceutical products and toiletry.

The form makes the product overpriced

A cut-out form, which is used for cut-outs, consists of a plotter, a cutting form from dies or a cutting knife. The disadvantage is that for each shape of a printed product a new form must be produced, which increases the final price. The form price depends on its complexity, on the length and shape of the knives. This type of a cut out is therefore suitable for larger printing runs. The price of the form is not included in the final price if it is used for several cut-outs and was not made-to-measure for the commission.

Using this type of a cut-out method, only shapes without details can be conducted. For example, it is not possible to cut out tiny letters. It is caused by limitations related to the form production as well as to the cut-out method which may result in curling of the cut.

Cut-outs without a form

Cut-outs for smaller runs can be carried out using a plotter. We do not need a cut-out form, as a movable cutting knife is used. A better option is a laser cut-out which is also referred to as digital cut-out. A laser beam radiating from a movable head is used to conduct the cut-out job. The head traces an image predefined in a computer.

A cut-out form in not required. The advantage of a laser cut-out is fine detail, which means tiny letters and detailed shapes can be cut out. Cut out angles are sharp and precise; it is not necessary to remove the rests. A laser cut-out is suitable for business cards, invitations, postcards or mock-ups in smaller runs. Besides paper, there are other materials which are suitable for a cut-out. They include foil, textile, various organic materials which can also be combined in layers. It is a quick and cheap cut-out method.

Engraving is another cut-out method using a laser beam. The image is not cut into the material, but it is engraved in the top layer of a paper which creates relief. Very thin materials are suitable for engraving too, as the depth of relief can be adjusted. Engraving is used for small runs, e.g., labels or product packaging, but also for marking products with dates of production, expiration dates or bar codes.

Cut-out data

As we have already mentioned, if a mistake occurs in a cut-out process, the whole printed product must be made again from the very beginning, as a cut out process is the last step in the production. It is therefore necessary to pay extra attention to the preparation of cut out data. The shape of the cut-out can be designed in a special program and subsequently the producer needs to be consulted about the shape and production possibilities. To design more complex cut-outs, it is necessary to use a special construction program.