Packaging die-cutting lines and design drafts typically need to meet the following requirements (taking common offset/flexographic printing processes as an example):
1) Files and Layers
Die-cutting lines, bleed lines, and crease lines (crimping lines) should be placed on separate layers for easy factory identification and inspection.
Common conventions (can be adjusted according to factory specifications):
Die-cutting (cutting) line: 100% magenta (M100) or spot color “die-cutting line”, usually set as a solid line.
Creasing (crease) line: 100% cyan (C100) or spot color “crimping line”, usually set as a dashed/thin line (some factories require you to draw solid lines, they distinguish them according to color codes).
Line width is generally 0.1–0.25pt (do not make it too thick to avoid accidental cutting/crimping), and must strictly coincide with the finished product dimensions.
2) Bleed (Very Important)
Typically, a 3mm bleed is required (2mm for small boxes/cardboard, 5mm for large cartons/corrugated boxes, depending on factory requirements).
Patterns, color blocks, and backgrounds must extend beyond the bleed line to prevent white showing after cutting.
3) Finished Size vs. Die-cut Line
The die-cut line = the finished outer frame (including the bleed edge, which is generally the bleed line). Do not draw it as a “net size line” but forget the bleed.
When folding boxes, the dimensions of structural elements such as “lugs/gluing/bottom locks” must be sufficient according to the material, thickness, and box shape to avoid assembly misalignment.
4) Line Relationships (Avoid “Clashing”)
The die-cut line and the creasing line must not overlap (otherwise, cutting and creasing simultaneously can easily cause crease bursting/misalignment).
Rounded corners, sharp corners, narrow edges, and long, thin tabs should avoid being too sharp/thin, otherwise die-cutting will easily deform, cause paper jams, and result in color bursting.
5) Text and Key Information
Text (especially barcodes, logos, and expiration date windows) should be at least 3mm (usually 3-5mm) away from the die-cut line to prevent it from being cut or crushed.
Barcode areas should avoid creases/seams, and sufficient quiet space should be left; for small font sizes, pay attention to the minimum font size limit for the material.
6) Color and Output
Design drafts are generally in CMYK (Pantone spot colors should be specified).
Common deliverables: AI/CDR/PDF, text converted to curves or packaged fonts; die-cut lines should generally not be cutouts/masks, but rather visible vector lines.
7) Proof Confirmation
For the first mold opening, it is recommended to make a white sample/die-cut pattern for trial folding: check the seam, bottom lock, flap, strength, and color bleeding.
If you tell me: box type (cardboard box/corrugated?), size, quantity, printing process (offset/digital/flexographic), I can provide you with a standard checklist of “die-cut line layers + line color + bleed” according to common factory specifications.
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