This article takes an in depth look at kiss cutting and its benefits.
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Kiss cutting is the process of precisely slicing through the top layers of a material, ensuring the bottom layer remains untouched. The word "kiss" reflects the light contact the blade makes with the surface, forming a pattern or cut that has just enough pressure to leave an impression on the surface without cutting through to the backing.
Kiss cutting machines are engineered to create a crack-and-peel interface, making it simple to remove the liner while keeping labels or stickers adhered for placement on a variety of surfaces, such as parcels or letters. This method utilizes digital die-cutting machines that carefully control the cutting force. An illustrative example of kiss cutting is a label sheet containing multiple stickers on a single page.
Kiss cutting is a widely used die cutting process to create custom gaskets, seals, pressure-sensitive adhesive labels, or protective pads that are easily separated from their liner or backing. This precision technique is essential in flexible material fabrication, particularly in industries such as automotive, electronics, packaging, medical devices, and signage where accurate, repeatable cuts of adhesive-backed materials are needed. By rolling gaskets or die-cut components, manufacturers can streamline production and assembly line workflows, making parts more manageable and efficient to dispense—similar to how toilet paper or paper towels are used on a roll. This roll format optimizes material handling, reduces waste, and improves throughput versus manually detaching individual sheets.
A crucial element of kiss cutting is the adhesive liner. In a kiss cut operation, the die penetrates the face material and adhesive layer, but stops short of cutting through the liner or backing paper, ensuring finished parts have an easy-to-remove release liner. Dies for kiss cutting are engineered in a wide variety of shapes, sizes, and depths of cut—ranging from under an inch for small electronics applications to several inches or more for industrial uses. The choice of die depends on factors such as substrate type, thickness, and the tolerance requirements of the final product.
Kiss cutting can be performed using several specialized cutting machines—each tailored to specific materials, production volumes, and design complexity. Machine types include rotary die cutters, flatbed die cutters, laser die cutters, thermal die cutters, CNC routers, cutting tables, plotter cutters, hydraulic and mechanical presses, and clamshell presses. Selecting the ideal kiss cutting technology is critical for achieving high cutting precision, material utilization, and process consistency—key factors in the manufacturing of high-quality custom gaskets, self-adhesive labels, and foam components. Below, we review the primary machine types and their advantages for industrial kiss cut applications.
Rotary die cutting is similar to rotary printing where the shape of the die is cylindrical and mounted on a rotary press. The web of material is fed into the press that has the cylindrical die and an anvil. As the material is fed through, the cutting portion of the die presses against the web and anvil to pierce the material to imprint the design.
The rotary process is executed swiftly, guaranteeing that the final image is consistently aligned and uniform. Rotary kiss cutting is ideal for high-volume production of labels, tapes, and thin flexible materials, offering tight registration and exceptionally high speed. Advanced rotary die cutters can feature integrated slitting, laminating, embossing, and rewind functions for inline finishing.
The core component of the flatbed cutting process is the steel rule, which consists of sharp metal strips shaped into the desired form. This steel rule is set into a hydraulic, electric, or mechanical press. The press is equipped with a feeder, an in-feed module, a cutting station, and a steel rule die assembly.
The feeder draws the material from the feed tray into the flatbed die press. At the cutting station, the steel rule die is mounted on an upper plate, while a lower counter plate, akin to an anvil, supports the material from below. Once the material is correctly positioned, the cutting plate descends gradually, pressing down to create the kiss cutting impression on the material. Flatbed die cutting machines are preferred for thicker substrates such as foam, rubber, cork, plastic, and composite laminates, where complex geometries or lower production volumes are required. Flatbed kiss cutting enables precise control of cut depth, making it a go-to solution for intricate part fabrication and short runs.
Laser die cutting uses a focused laser beam to cut materials accurately and efficiently to custom shapes. The precision and accuracy of laser cutting allows for the cutting of complex and intricate designs at exactly the correct depth and dimensions. Since laser die cutters can be programmed to move in any direction and cut to any depth, they are capable of performing cuts quickly and effortlessly using input data and programmed requirements.
Laser kiss cutting delivers consistent, burr-free edges and superior detail resolution, making it ideal for prototyping, short runs, or applications with frequent design changes. With the ability to cut adhesive-backed films, pressure-sensitive tapes, and specialty substrates without a physical die, laser die cutting minimizes tooling costs and enables rapid design iterations—making it a top choice for industries requiring custom gaskets, protective films, and flexible circuits.
Thermal die cutting is a modern advancement in die cutting technology, designed for materials that respond to heat-based shaping. This technique employs controlled heat to precisely displace small sections of material, forming the intended shape without affecting other parts of the material. Despite the use of concentrated heat, thermal die cutting does not cause distortion or damage to the surrounding material.
Thermal dies are crafted from a chemically etched magnesium alloy and come in various sizes and thicknesses. One side of these dies is photosensitive, enabling the thermal process to work effectively. A significant advantage of thermal kiss cutting is its ability to create highly detailed and intricate patterns, especially when working with layered adhesive films, pressure-sensitive foams, or nonwoven substrates. This method is often chosen for medical device components, conservation materials, or electronics due to its gentle handling and clean, precise edges.
A cutting table operates similarly to a flatbed die cutter, but it differs in that it doesn’t use a die for cutting. Instead, it employs an arm that moves a cutting tool across the surface of the material. These tools can be attached to one or more beams, and various blade types are available to control the depth and width of the cut. A programmable controller manages the movements of the beams and cutting tools, directing the specific tasks to be carried out.
A kiss cutting module can be mounted on a beam, allowing for precise and efficient cutting of impressions into the substrate once it is programmed. This setup ensures clean cuts by adjusting the cutting tool to the exact depth required. Cutting tables are particularly effective for kiss cutting materials such as vinyl, film, laminates, PVC, and pressure-sensitive adhesives. This digital die cutting approach is ideal for prototyping, digital printing applications, and projects where frequent design changes or short runs are needed.
A plotter kiss cutting machine is an automated system designed to feed and cut materials. It can handle various sheet sizes, from A4 to tabloid, or even work with rolls of material. Designs for cutting can be sent to the plotter via a computer or uploaded directly from a USB drive. The machine’s programming interface allows for easy adjustment of the cutting depth and shape.
Offering high versatility, plotter kiss cutting systems are suitable for low to medium production runs, custom prototyping, and the creation of unique shapes or intricate sticker designs. These machines excel at handling diverse materials including vinyl, specialty films, reflective tapes, and printed adhesive media, and are frequently chosen for the custom label, decal, or signage industries. The digital workflow allows for cost-effective short runs and facilitates rapid order turnaround.
A computer numerical control (CNC) router is a device operated by computer software that cuts and shapes various materials. This versatile tool can execute multiple types of cuts based on designs created in CAD, which are converted into G-code instructions for the CAM system using vertical, horizontal, and perpendicular coordinates.
When a kiss cutting knife cartridge is mounted on the Z axis, a CNC router can be adapted into a large-format kiss cutting machine. An adaptor is used to integrate the kiss cutting knife with the existing spindle and tangential knife tools. The kiss cutting attachment features adjustable pressure settings, allowing it to handle different material thicknesses. CNC routers with kiss cutting capabilities are ideal for large-format projects, industrial gasket fabrication, and flexible packaging components where accuracy, repeatability, and multi-material processing are critical considerations.
Hydraulic and mechanical presses are known for their ability to supply a great deal of force to cut hard, solid, and difficult to form materials. They can also be adapted for high speed kiss cutting using web feeding. Unlike the cutting of metals, the hydraulic and mechanical kiss cutting presses have a lower adjustable plate that can be set for the point of the cut as well as the depth. On each side of the lower plate are rollers that advance the material and guide it into the proper cutting position. For self-adhesive products, a rewind station is available to neatly collect the finished kiss cut material.
Hydraulic and mechanical presses are often the preferred choice for kiss cutting thick gasket sheets, high-strength foams, and rubber or specialty plastics where robust force and fine-tuned pressure adjustment are required for optimal cut quality. Their adaptability and high throughput make them valuable for automotive, aerospace, and industrial OEM production lines that require both volume and precision.
Clamshell kiss cutting machines resemble traditional printing presses in their design. The material to be cut is placed on a flat platen or surface, while the cutting tool is mounted on the top part of the clamshell structure. The name "clamshell" aptly describes the machine’s design, which consists of two sections—the upper and lower halves. During operation, these halves come together, and the die presses into the material to perform the cut.
There are various designs for clamshell die cutting machines. In some models, the upper section moves down to meet the lower section, while in others, the lower section moves up toward the upper one. These machines can be adjusted to handle different material thicknesses and can be finely calibrated for precise cutting. Clamshell kiss cutting presses are valued for their reliability, durability, and ability to run heavier dies—making them well-suited for both small-batch and large-scale production environments where part complexity or thickness demands a robust solution.
Choosing the right kiss cutting machine depends on key factors such as material thickness, adhesive properties, design complexity, required tolerances, production speed, and batch size. By understanding the strengths and applications of each kiss cutting technology, manufacturers can optimize their production process, reduce costs, and ensure high-quality, precision-cut adhesive products and gaskets for demanding end uses. For detailed guidance or to request custom kiss cut parts, consult with an experienced die cutting supplier who can match your specifications to the right machine and process.
Kiss cutting machines are essential in modern industries as they provide precise and efficient production of labels, stickers, and products with adhesive backs. This capability simplifies application processes and boosts productivity in fields like packaging, branding, and manufacturing. Below, we review several brands of kiss cutting machines available in the United States and Canada, highlighting specific models and their distinctive features, functions, and capabilities:
Features: The Delta ModTech Spectrum is a flexible modular converting system designed with kiss cutting capabilities. It delivers high precision and accuracy when cutting materials like films, foils, and adhesives. This machine includes a servo-driven web transport system that ensures exact control and registration. It allows for rapid changeovers and adaptability to various kiss cutting patterns and designs. Additionally, the Delta ModTech Spectrum features advanced tension control and waste management systems to enhance production efficiency.
Features: The Spartanics Finecut-Plus-Rotary is a rotary die cutting machine equipped with kiss cutting capabilities, providing accurate rotary tooling for precise cuts on different materials. It boasts high-speed performance for efficient production and includes an advanced control system for managing depth and pressure during kiss cutting. This model can function independently or be integrated into existing production setups.
Features: The AB Graphic Digicon Series 3 is a modular finishing machine equipped with kiss cutting capabilities. It provides high-speed processing and versatility for cutting labels, tags, and other products. The machine includes an advanced registration system to ensure precise alignment and cutting accuracy. Additionally, it supports extra finishing processes like laminating, varnishing, and embossing. The Digicon Series 3 is designed with user-friendly controls and intuitive software for straightforward operation.
Features: The Trotec Laser SP Series comprises laser die cutting machines designed for a broad range of cutting tasks. These machines use high-powered CO2 or fiber lasers to deliver precise and clean cuts on various materials such as films, foils, and adhesive-backed products. They offer flexibility for operations like kiss cutting, through-cutting, perforating, and other detailed cutting tasks. The non-contact cutting process eliminates the need for physical dies, allowing for quick job changes and reduced setup times. The SP Series also features advanced software for design and control, ensuring accurate cutting and enhanced productivity.
Features: The GM E-Cut is a high-speed rotary die cutting machine designed with kiss cutting capabilities. It provides precise and accurate kiss cutting across a variety of materials, including those with adhesive backs. The machine features an intuitive touchscreen interface for straightforward operation and setup. Additionally, it includes advanced servo technology for accurate control of cutting depth and registration. The GM E-Cut is compatible with various digital printing systems for seamless integration.
Note that the availability and features of specific models may change over time. For the latest information on models that meet your needs, it is recommended to contact the manufacturers or their authorized distributors.
Kiss cutting is frequently used in the printing industry, particularly for producing labels. The cutting pressure is adjusted so that it partially cuts through the printed sheet. While kiss cutting dies and standard cutting dies are quite similar, there are some minor differences between them.
Rule joints and miters must be precisely calibrated to prevent cutting through the material. Die cutters for kiss cutting are typically set to a depth ranging from 0.937 to 0.918 inches. Variations in the stock's surface can result in uneven and inaccurate cuts.
Steel rule dies are a simple form of die that is made by cutting slots in a rigid firm surface such as wood laminate, aluminum, rayform, acrylic, and Lexan. The size of the slot is between 0.028" and 0.056" (0.7 mm and 1.4 mm) and is normally cut by a laser. The slot is cut into the base in the shape of the form of the design to be cut.
A narrow strip of steel, known as a rule, is placed into the slot so that it extends above both the slot and the base surface. The height of this strip above the slot and base determines the cutting depth of the die. The upper edge of the strip is sharpened to effectively cut or pierce the chosen material.
Thermal dies offer high precision and can create intricate patterns. They are constructed from magnesium plates etched chemically with a design. Available in various sizes and thicknesses, these dies feature a photosensitive emulsion coating on one side. Thermal kiss cutting dies are commonly used for graphic marking and kiss cutting vinyl.
Rotary dies are cylindrical in shape and come in two types—flexible and solid. Flexible rotary dies are made from metal sheets engraved with the cutting design. In contrast, solid rotary dies are single-piece cylinders that can be mounted on a rotary die cutter.
Flexible dies are more affordable and simpler to produce compared to solid dies. They can be easily replaced if damaged and are attached to a magnetic cylinder that secures them in place. However, flexible dies are less durable, have a shorter lifespan, and are limited in the types of materials they can cut.
Solid rotary dies are more robust and can endure frequent use. They are capable of making deeper cuts and handling more complex blade designs. Ideal for long production runs, solid dies have a longer lifespan and greater durability.
Achieving optimal productivity is a key goal for manufacturers. Efficient assembly of parts and components is crucial for business success. Utilizing kiss cut parts enhances the handling and efficiency of production and assembly processes.
Kiss cut parts are adhered to a backing material like a silicone release liner or carrier tape. These parts can be delivered in rolls or cut into specific sections as needed. One significant advantage of kiss cutting is its precision; it completely cuts out the component's shape while leaving the backing intact.
Kiss cutting is a widely used technique for producing pressure-sensitive labels. This method involves cutting the perimeter of each label precisely, which facilitates easy removal of the peel-off label. Labels can be manufactured in sheets or rolls, and can be customized into any shape, design, or configuration.
Kiss cut gaskets are manufactured from a range of materials such as rubber, vinyl, nitrile, and flexible graphite. The material is adhered to a pressure-sensitive adhesive backing, and the gasket shape is then cut out. Gaskets are supplied in rolls for convenient removal and application by assembly operators.
The production process benefits significantly from the ease of removing and applying self-adhering gaskets from the roll, which boosts efficiency and saves time.
Every producer aims to make their labels visible, distinct, and recognizable. Kiss cutting iron-on labels has become crucial in the printing and design of labels that can be easily applied to various fabrics.
The kiss cutting method enables companies to create labels in custom shapes, styles, and designs, resulting in a professional and attractive look that is easy to read. Labels can be made in any size, configuration, color, and texture, offering a smooth and elegant appearance. They can feature elements such as company logos, employee names, and positions, contributing to a sense of professionalism and stability.
Kiss cutting is used for creating adhesive tape solutions in a wide variety of shapes, sizes, and configurations. Adhesive tape of varying widths is fed into a kiss cutting machine. A die cuts the desired shape onto sheets or rolls. The pre-cut designs make it easy to remove the design from the rolls to be applied to any surface.
Adhesive tape shapes are utilized for various applications such as car emblems, pricing labels, optical pads, abrasive materials, and other situations where quick and easy access to adhesive stickers is essential.
Kiss cutting is employed whenever a shallow cut is needed. This method is used to protect the backing or one side of a material while making the cut. Products like gaskets, valves, and plastic screen protectors are commonly produced using kiss cutting.
While vinyl is a popular material for kiss cutting, a wide range of specialized materials can also be shaped and transformed through this process. Essentially, any fabric that can be cut by a die can be kiss cut.
Kiss cutting is extensively used for manufacturing gaskets and seals, which are produced in sheets or rolls with an adhesive backing. The materials used include various types of rubber, polymers, and plastics, all of which can be effectively configured using the kiss cutting technique.
Vinyl is a prevalent material for kiss cutting, especially suited for thermal kiss cutting due to its ability to endure the heat involved. Industrial kiss cutting of vinyl utilizes advanced computer-controlled machines equipped with a coarse roller to manage the feeding process. Vinyl's popularity as a kiss cut material stems from its superior durability compared to many other options.
Butyl rubber is a popular choice for gaskets due to its lower porosity compared to other rubber compounds and its flexibility at sub-zero temperatures. Gaskets made from butyl rubber are tear-resistant, well-suited for applications involving gases or compressed air, and offer excellent shock absorption.
Closed cell sponge material is known for its resilience, high temperature stability, and chemical inertness. It is available in various densities, including soft, medium, firm, and extra firm, and also comes in low compression and flame retardant versions. This material is offered in a range of colors and can be customized to suit any specific application.
Viton rubber gaskets are renowned for their outstanding thermal stability in high-temperature environments. They exhibit resistance to hydrocarbons, chemicals, fuels, and oil degradation. These characteristics make Viton gaskets the preferred choice for automotive, aerospace, and petrochemical industries.
Kiss cutting is a favored technique for creating foil labels. These labels can be designed with various graphic design software, incorporating diverse colors, shapes, configurations, and fonts. Foil kiss cutting demands higher precision and attention compared to other materials due to the unique properties of foil.
Kiss cutting of stickers is a well-known application of this technique. This method is used for creating address labels, stamps, toy stickers, product labels, and annual license plate stickers. Typically, stickers start as a sheet of material—such as vinyl, paper, plastic, or another fabric—backed with adhesive and are then processed through printing, which may include kiss cutting.
After kiss cutting, stickers are sometimes "weeded," a process that involves removing the excess material around the sticker to make it easier to access. Self-adhesive kiss cut postage stamps in strip or roll form were introduced in the early 1990s.
Similar to kiss cut sheets of self-adhesive stamps, kiss cut foam is commonly used to provide self-sticking protection for container sides and automotive parts. The cushioning properties of foam make it an excellent choice for gaskets or sealing materials. Foam types for kiss cutting include both closed and open cell configurations, adaptable to various applications.
Foam’s formability is a key reason for its widespread use in kiss cutting die applications. It can be precisely cut with minimal energy or force, making it highly versatile for detailed work.
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