Traditional diecutting in the bindery has been around for many years. There are many types of diecutting. In this case we are discussing diecutting for the commercial print and light packaging industry. Rotary diecutting is one of those processes that has always given a printed piece a look and vision of class, elegance, function, and, most importantly, higher profit margins for the manufacturer. Diecutting had traditionally been an area of high investment, complex die creation, highly trained operators, and long runs.
Today diecutting is getting a makeover. With the advent of digital print devices, shorter runs, fewer skilled operators, tighter margins, and turn-around, diecutting is now entering a new phase of simplicity, with the same qualities of higher-end machines in a small package. New small-format rotary magnetic diecutting units from several manufacturers allow the customer to use magnetic dies from a plethora of sources around the world. Many of the die manufacturers have been making these types of rotary magnetic dies for the flexographic, forms, and packaging industries for years. The dies have been manufactured for runs of hundreds of thousands to millions, depending on the requirements of the run length and substrate. Typically the rotary diecutting was used for webs and flat bed for cut sheet. Cut sheet diecutters are for medium to long runs but are very high in price ($450,000 and up). Older flatbed letterpress devices are typically modified for diecutting but hold mediocre registration, are complex to set up, and many times are unsafe.