Preparing Your Artwork: Flexographic Printing With Rotary Die Cutters

Rotary die cutting is an effective way to create unique boxes that stand out. A specific die capable of producing intricate, custom shapes is created, resulting in uniform, accurate cuts that are ideally suited for flexographic printing. Flexographic printing and rotary die cutting are the perfect partners when you require high-quality prints paired with interesting or custom-shaped materials.

Setting up Your Artwork for Flexo Rotary Die Cut Printing

Bolt Boxes will provide an approved die line on which to design your project. Your artwork must be designed precisely on the template provided.

All flexographic printing requires the one-time creation of print plates. Any changes, revisions, adjustments or additional proofs required will increase the preparation time and impact the plate costs.

Before we start, let’s go through some common terminology you may encounter while creating your design.

Checklist for Creating Perfect Flexo Print-Rotary Die Cut Designs

  1. Get your template: Obtain your die line template from Bolt Boxes before you start working on your design.
  2. Create art in a vector format: Adobe Illustrator or eps. files are preferred.
  3. Consider flexo printing color limitations and designate PMS (Pantone Solid) colors: Certain inks, including neons and metallics, are unsuitable for this printing method. Keep this in mind during the design process and take careful note of the specific Pantone color codes you are using in your design.
  4. Refer to the specific design specs below while creating your artwork:

5.   Note any exceptions: If your art is not supplied to a die line, please specify the size of the art and its intended placement on the panel.

6. Contact us if you have questions: A friendly team member at Bolt Boxes is only a call away and we are excited to help you create the best boxes to showcase your products.

Common Applications of Flexographic Printing With Rotary Die Cutters

Flexographic printing is the ideal economical printing method for bulk orders. Although setup takes longer than digital printing, once the plates have been created, they are always ready for future runs. The die-cutting feature makes it possible to produce custom-shaped boxes and labels, often with intricate details that wouldn’t be possible without the specific die. Some common examples of flexographic printing include:

What to Do With Structural Samples

Carefully evaluate and test every aspect of the samples to determine whether the design and dimensions are a perfect fit for your product. While structural samples may arrive fully assembled, final production orders will be shipped flat unless otherwise noted.

Here are factors to consider:

CAD-cut structural samples may differ slightly from final press run boxes with slight variances, like inconsistent material rigidity along score lines or edge crush. These inconsistencies do not affect the overall quality, fit, form and function being assessed.

Contact Bolt Boxes to Create Unique Flexo Printed Rotary Die Cut Boxes

Understanding the nuances of the different printing methods can be confusing. The experienced team at Bolt Boxes is here to help you make the best decisions so you can confidently design boxes that you will feel proud of. Contact us today with any questions or more information about how to get started on creating the perfect boxes for your product.