NEW ERA PRINT SOLUTIONS · MISSISSAUGA

Custom Die Cutting

Change the outline, add a window or build a folded structure. A custom die can cut, crease or perforate suitable stock for practical and decorative print designs.

Illustrative leaf-shaped die-cut window and rounded corner in an ivory folder, revealing sage paper beneath.
Illustrative design concept; final artwork and specifications are confirmed with your order.

THE PROCESS, UP CLOSE

Watch die cutting in action

Watch how the die cuts the sheet, then explore the shapes and openings below. Send us your idea so we can discuss the outline and paper.

Leaf-shaped die-cut window and rounded corner in an ivory folder, revealing sage paper beneath.
Leaf-shaped opening • the sage layer is visible through the cut
Leaf-shaped die-cut window and rounded corner in an ivory folder, revealing sage paper beneath.

Leaf-shaped opening • the sage layer is visible through the cut

TAKE A CLOSER LOOK

A cut-out that becomes part of the design

The leaf-shaped window is an actual opening in the ivory concept folder. Sage paper beneath supplies the colour through that opening. The rounded outer corner and internal window show how changing the physical shape can support the printed design.

What to notice

  • The window removes material rather than printing a leaf.
  • The inner layer is visible through the opening.
  • Material around the cut keeps the panel connected.

Illustrative design concept, not a print proof.

Plan the details that matter

Reveal what is inside

Design direction
A window can frame an inner illustration, a second paper layer or a product. Design the visible content together with the opening.

What to send us
Provide the window outline and a view of the layer or item behind it.

Create a distinctive outline

Design direction
A shaped card, invitation or mail piece can make the format part of the message. Keep enough usable space for the information people need.

What to send us
Supply the final outline and check that the format still suits your envelope, display or delivery method.

Support a functional structure

Design direction
Folder slots, sleeves, tabs and carton panels need to work when handled or assembled. Appearance and structure should be reviewed together.

What to send us
Include the intended folds, tabs and assembly details in a clearly labelled dieline.

Your project checklist
0 of 4 planning steps ready

Use this guide to plan your idea. We’ll check the paper, artwork and finishing details before confirming the job.

Can a printed mockup prove that the cut will work?

It can help communicate the idea, but a flat screen image does not prove structural fit. Complex folds or packaging need a suitable physical mockup and production review.

What if an opening sits close to an edge?

Narrow bridges of paper can become fragile. Flag these areas for review and allow the dieline to be adjusted for the chosen stock and intended handling.

BEFORE YOU PRINT

Choose a shape that works in the hand

Think about how someone will hold, open or assemble the piece before choosing the shape.

An outline people can handle

Picture the finished piece in someone’s hand. Thin extensions, sharp inside corners and narrow strips of paper can be fragile or difficult to remove from the sheet.

A window with a purpose

A cut-out can reveal a photograph, insert or product. Check what sits behind the opening and whether the surrounding material gives enough support.

Check the assembled shape

Folders and cartons need more than a cut line. Mark scores, perforations and glue areas separately, and review the assembled form before committing to a full run.

Choose the right format

Custom outlines

Rounded corners, shaped cards and distinctive mail pieces.

Windows and cut-outs

Reveal an inner panel or product while maintaining enough material around the opening.

Creasing and perforation

Plan folds, tear-off sections and assembly features within the dieline.

Where custom die cutting works

  • Cards, postcards and invitations: create a shape that supports the message without sacrificing readable space.
  • Door hangers and tickets: combine an opening or perforation with the functional layout.
  • Pocket folders, cartons and sleeves: develop a structural dieline before placing print and special finishes.

How the process differs

Cutting removes material; creasing helps folds; perforation creates a controlled tear. Keep each operation labelled on a separate production dieline. Review a physical mockup for cartons or complex folded pieces before a full run.

Prepare a clear dieline

  • Supply print artwork and a separate vector dieline at the same scale. Label cuts, creases and perforations distinctly.
  • Extend printed backgrounds past cut lines according to the approved template, and keep text within the safe area.
  • Keep glue flaps and structural areas clear where needed. Check assembly with a physical sample for packaging.
  • NEPS reviews the die, material and production sequence before quoting.

Finishing examples

Questions before you order

Is a cut line the same as a score line?

No. A cut separates material, a score prepares a fold, and a perforation creates a controlled tear line. Identify each operation clearly on the approved dieline.

Can you work from my custom shape?

Send a vector dieline with the finished dimensions and intended use. NEPS reviews the shape, stock, structural details and tooling before confirming production.

Should the dieline print on the finished piece?

The dieline is a production guide, not ordinary printed artwork. Supply it as an identified layer or separate file and confirm the approved file setup with NEPS.

Have a shape in mind?

Send a sketch or vector outline, the size, quantity and paper you’re considering. For a folder or carton, include what it needs to hold and how it should open. We’ll check the die and construction before quoting. You can discuss samples with our Mississauga team; we also ship across Canada. Production starts after artwork approval, with shipping time added separately.

Need help with the design? Explore graphic design services.

Tell us what you want to make

Need to send artwork or attachments? Email info@neps.ca. This form does not upload files.