Die-Cut Roll Labels — How to Get a Custom Shape That Actually Prints Well

Die-cut, kiss-cut, or through-cut?

Three phrases you'll hear us use:

• Kiss-cut — cuts through the label only, NOT the liner. The label stays on the backing and peels off cleanly. This is the default for roll labels.
• Through-cut — cuts label AND liner. Rare on roll product; used mostly on sheeted labels or matrix-removed packs.
• Die-cut — a custom shape (not a rectangle). Requires a physical steel die matched to your artwork.

Design rules for a clean die-cut

• Minimum radius on corners: 0.0625" (1/16"). Sharper corners tear during matrix removal.
• Minimum die-line stroke: 0.5 pt in your design file.
• Give critical artwork at least 0.125" clearance from the die-line — the same safe area rule as rectangular labels.
• Draw the die-line on its own layer named 'DIELINE' as a spot color named 'CutContour' or 'Die Line'.
• Avoid sharp points less than 30° — they lift, curl, and fray in the field.

Tooling fees — one-time, then free forever

• Simple die (single curve, oval, rounded rectangle): $60 one-time
• Moderate die (multiple curves, one interior cutout): $95 one-time
• Complex die (multiple cutouts, sharp features): $145 one-time
• After the first order, the die is stored at our facility and reused free on every reorder.

Download rectangular templates first, then adapt

Even for die-cut work, we recommend starting from a bounding-box rectangular template — it enforces the correct bleed and safe area. Draw your die-line inside that template on its own layer, then export the PDF.

• 3" × 3" template (square starting point): /api/templates/3x3.pdf?label=Die-Cut+Bounding+3x3
• 4" × 4" template: /api/templates/4x4.pdf?label=Die-Cut+Bounding+4x4
• 5" × 5" template: /api/templates/5x5.pdf?label=Die-Cut+Bounding+5x5

Full spec at koltprinting.com/shop/product/paper-roll-labels — pick 'Custom die-cut' in the shape dropdown when you order.