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Ten Processes For Adhesive Tape Die Cutting

July 19, 2023

Die-cutting is a very common process in the processing of adhesive tapes, especially in the automotive and electronics industries.
In short, it involves cutting the tape into the desired shape for various applications using a special die.
The different die-cutting processes for adhesive tapes have their advantages and disadvantages, including the basic half-cut, multi-layer laminated material die-cutting, gapless and gap die-cutting.

Half-Cutting Process

A basic process for die-cutting rolls and sheets.

  • Characteristics: A die-cutting process that cuts through a single layer of material without damaging other materials, i.e. cutting through just one layer of thickness.
  • Cost: The simplest and most economical form of die-cutting, more economical than full-cutting and multi-layer lamination die-cutting.

Multi-layer Laminated Material Die-Cutting

Features: The process of die-cutting multiple layers of laminated material at the same time, with the depth of cut determined by the length of the blade.


  • Suitable for die cutting where complex functionality needs to be achieved
  • Multiple die-cutting processes can be completed in one step, saving time
  • A single cut ensures precise spacing between multiple contours on a single product.

Cost: Multiple die-cutting processes in one step require more complex dies, but are still more economical than using two or more separate dies.

Gapless Half-Cutting

Features: No gaps between die slices to achieve side-by-side.

Advantages: 100% utilization of raw material, no trim or gap waste to remove, therefore no losses, but trimming is still necessary.


  • Not all materials/adhesives are suitable: viscoelastic materials tend to stick back
  • Difficult to separate the die-cutting sheet from the release paper.
  • The die-cutting quality of die slices cannot be checked visually.

Cost: Compared to die-cutting with gaps, it is cheaper to produce because of the almost loss-free production and the fewer production steps required.

Gap Die-cutting

Features: Gaps exist between the die slices and the gaps can be adjusted exactly to the customer's requirements.


  • Suitable for the production of die slices of various shapes
  • The design of the peeling head can be achieved
  • The gap between die slices is more suitable for semi-automatic and automatic applications

Disadvantages: Higher material losses compared to gapless production


  • Higher processing costs compared to gapless production, requiring the purchase of customized die-cutting tools.
  • Higher costs due to wastage and additional production steps. To further expand on the art of tape die-cutting, we also need to understand some of the specially designed die-cutting solutions.

Perforation Design

The perforation is done through all layers of material. This process can be combined with a multi-layer lamination die-cutting process, where only specific parts of the die-cut are perforated.

Positioning Tear-off Design

The purpose of the positioning tear is to hold the die sheet in a specific position on the release sheet, while the rest of the profile is completely cut. Therefore, there is no through-hole outside the die cutter and the tearer holds the die cutter to a few small points on the web/sheet. As part of the glued zone design, the die slice is divided into glued and unglued zones according to the customer's requirements.

Design Of Back-Cutting Release Paper

Pre-slit release paper, commonly used as an optional tear-off hand during production, the back-cut design optimizes the application method of the die-cutting sheet and provides more convenient operability.

Positioning Feature Design

Positioning features are designed to help the user determine the exact position of the die cutter. Positioning can be achieved by punching through holes in the die slices or by printing on the die slices to create visual positioning information. Product identification features.

Product identification features can be designed to provide product information to the producer or end user. Product identification features include instructions for use, product codes, or left and right side markings to reduce application errors.

Stamp Line Design On Release Paper

A series of intermittent cuts in the release paper, similar to a stamp line, allow for easy separation of the die-cut from the web or sheet. The die slice can be separated from the web together with the release paper.

Peel Head And Extended-release Paper

Peel aid: The non-adhesive part of the peel aid can be touched and is used to remove or position the die sheet.Extended-release paper: The extended-release paper can be touched and used to remove or position the die slice.

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