From shaped business cards and custom stickers, to intricate direct mail pieces and short-run packaging, die-cutting remains a key part of production for many printers. Here, we analyse some of the market’s latest developments Gain an Advantage with a Die-Cutter Investment Die-cutting has become an increasingly important capability for print businesses looking to add value and differentiate their offerings. The ability to produce creative, eye-catching applications can help print service providers (PSPs) win new work and increase margins in competitive markets. The range of die-cutting technologies available today is broader than ever. Traditional mechanical systems continue to play a key role in high-volume production, while digital die-cutting solutions offer greater flexibility, faster turnaround times, and cost-effective production of short runs and personalised jobs. Advances in automation, precision, and workflow integration are also making it easier for businesses to incorporate die-cutting into their operations. Here, Print Monthly takes a closer look at some of the latest die-cutting technologies on the market, exploring the advantages of different approaches, and considering how PSPs can select the right solution for the core applications they offer to customers. Speed, Flexibility, and Quality Up first to comment is Craig Harry, head of sales for Duplo UK, who says the biggest trends in this market are a shift towards shorter runs, increased versioning, and growing demand for premium, custom-shaped work. As such, he says the conversation is moving beyond simple shape cutting, with customers now demanding speed, flexibility, and production-grade quality in one workflow. For Harry and Duplo, this is where the DSM-1000 comes into play. He explains how the machine gives commercial printers a “serious” B2 route into cartons, folders, shaped cards and display work, while the PFi Blade B2 and PFi DI-CUT 310 support smaller bespoke jobs, and repeat shaped applications where agility matters. But how are printers and converters balancing the need for faster turnaround times with pressure on costs and productivity? Harry offers an explanation: “They are doing it by removing touchpoints, bringing work back in house, and investing in systems that spend more time running than setting up. “That is exactly where the DSM-1000 makes a difference. It runs at up to 3,100 sheets per hour, supports fast die changeovers, and can automate waste removal with the separator unit, so the gain is not just headline speed but real production time. “The PFi DI-CUT 310 plays a similar role for repeat rotary jobs, processing up to 4,000 sheets per hour with registration mark compensation, while the PFi Blade B2 gives printers a flexible way to produce samples, prototypes and short bespoke runs. The common theme is simple – faster turnaround only works if the finishing step stops being the bottleneck.” Harry also talks up the importance of automation, describing this as central and that when it comes to die-cutting, automation is no longer an upgrade, but instead is the operating model. “On the DSM-1000, operators get PC control, unlimited job memory, integrated registration mark correction, multi cut capability, and optional barcode driven recall,” he explains, adding: “The PFi DI-CUT 310 DIE-CUTTING | ROB FLETCHER 52 Issue 361 - July | August 2026 email: editor@printmonthly.co.uk
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