How are die cut stickers made?

Have you ever wondered how a die cut sticker is made? Or what happens between approving your design proof and receiving your stickers?

Let's take a look behind the scenes and see how custom die cut stickers are made.

Definition: What exactly is a die cut sticker?

When a sticker is die cut, it's cut to the shape of your sticker design, usually a custom shape.

So die cutting refers to the shape or cut of your sticker. Not the material, how it's printed, or anything else.

A die cut sticker looks like this:

What are die cut stickers made of?

The short answer: anything! Die cut stickers can be made from any material because the term "die cut" refers to how it's cut, not what it's made of.

You can choose your ideal material by browsing our materials page. The most common options are either paper-based or plastic-based. Let's break those down.

Plastic die cut stickers

Plastic die cut stickers are our most popular option. They're also known as die cut vinyl stickers. These come in a variety of colors including white, clear, holographic, glitter, silver, and gold.

All of these plastic materials have similar features: they’re waterproof, dishwasher safe, UV resistant, and highly durable.

They also use a medium-strength adhesive that sticks to almost any surface, making them ideal for general-purpose stickers and labels.

There are different types of plastic used in stickers and labels.

Polypropylene is a favorite because it’s durable and easier to recycle. PVC (often called vinyl stickers) is a bit harder to recycle but tends to be more flexible and even more durable.

Both options create excellent stickers and labels that won’t fade outdoors, resist tearing, and are available in matte or gloss finishes.

Paper die cut stickers

With our biodegradable paper stickers, we offer a plastic-free but high-quality alternative.

These paper stickers are made from sugarcane fiber, linen, and hemp, no wood at all. This makes them sustainable and compostable, a great choice for eco-conscious brands.

Paper stickers are ideal for short-term or indoor use. They’re affordable and easy to recycle.

Here’s an example:

Eco-friendly die cut sticker options

Looking for something more sustainable and water-resistant?

Our eco-friendly die cut stickers are made from wood pulp sourced from sustainable forests. The material looks and feels like plastic but is completely compostable.

These stickers come with a glossy finish and can be cut into any shape, just like our plastic options. We offer them in all the same colors, and they're perfect for product labeling.

Recommended read - What are stickers made of?

Adding the perfect finish

Once your custom cut stickers are printed, we add a protective laminate.

While this step is optional for some suppliers, we always laminate plastic and compostable stickers and labels.

We highly recommend lamination for stickers used outdoors or exposed to moisture. The clear laminate keeps your design protected from scratches and fading.

Matte stickers usually have a frosted look, while gloss stickers offer more vibrant colors.

We apply a gloss finish by default because it emphasizes the color and quality of your design. It also gives clear stickers better transparency. Check out our product images to see for yourself!

How can I get matte die cut stickers?

There are a few ways you can get custom matte stickers:

• For orders over $300, just add a note when placing your order. We use that threshold to set up matte lamination per order.
• Choose a sticker material that already has a matte finish, like our biodegradable paper stickers.
• If you have a unique project, contact our customer service team, we’re happy to help.

What is digital die cutting?

Traditional die cutting uses a sharp metal blade to punch your design shape. Think of it like a custom cookie cutter.

Once made, the die can be reused for large quantities of stickers with the same shape.

That makes die cutting cost-efficient for bulk orders but more expensive for small runs since each die is custom-made.

These days, most sticker makers use digital cutting instead.

Digital cutters don’t need physical dies. They use a digitally controlled blade or laser. A built-in camera finds the registration marks on your print to ensure precise cutting.

In your digital proof, the cutline appears in pink (for through-cuts) or green (for kiss-cuts).

This method lets us create custom shapes quickly without needing to make a die.

Who invented die cutting?

Die cutting started during the Industrial Revolution as a way to make uniform parts more affordably.

In the early 1800s, artisans used handheld knives and templates to cut shapes. Eventually, they moved to custom metal dies and cutting presses, especially in the shoe industry for cutting leather.

By the late 1800s, die cutting expanded into other industries, including sticker and label production, where it’s still used today (source).

Can you make die cuts without a machine?

You don’t necessarily need a die cutting machine, especially for basic shapes. You can buy pre-cut sticker sheets to print at home.

But if you want perfect cuts or plan to make a lot of stickers, manual cutting can be time-consuming.

You might want to invest in a digital die cutter. Popular machines include the Silhouette and Cricut models.

Ready to get your own die cut stickers?

Still unsure? Try a custom die cut sticker sample pack. It’s a low-risk way to test different materials and see what works best for you.