Die-Cut Stickers
Short answer
Die-cut stickers are plotter-cut to any vector contour — round, oval, a logo silhouette or a fully custom shape. The artwork needs a separate contour line and 2 mm of bleed beyond it. A minimum 2 mm radius at corners is preferred.
Rectangular stickers are everywhere — which is exactly why a die-cut sticker gets noticed. When the contour follows the shape of the logo, the sticker stops reading as 'printed paper' and reads directly as a brand mark. Plotter cutting does this on any vector shape. Die-cutting has its own technical rules, though, and almost every problem traces back to the same handful of artwork mistakes. This page sets those rules out.
Key facts
- Technology
- Plotter (contour) cutting
- Shape
- Any vector contour
- Cutting mode
- Full cut or kiss-cut
- Contour line
- Separate layer in artwork
- Bleed
- 2 mm beyond the contour
- Minimum radius
- 2 mm at corners
- Material
- Vinyl, paper, clear film
- Quote
- Timing by agreement
The three areas in contour cutting
Just as with a business card, a die-cut sticker has three areas. The outer one is bleed: the printed image must extend 2 mm beyond the contour line so no white sliver appears if the cut drifts. The middle one is the contour line itself, where the plotter cuts. The inner one is the safe area, 3 mm inside the contour, where all text and important detail must sit. Plotter cutting has a slightly wider tolerance than mechanical guillotine cutting, so these areas matter even more here.
- Bleed: 2 mm beyond the contour
- Contour line: where the plotter cuts
- Safe area: 3 mm inside the contour
- Text near the contour — the most common mistake
Which shapes work and which do not
A plotter cuts almost any shape, but two limits are real. First, very narrow necks: if a shape has a thin bridge between two wider parts (a fine element of a letter, say), it can tear during cutting or weeding. Second, sharp points: a tip narrower than 90 degrees often lifts during cutting and frays over time. So we recommend a minimum 2 mm radius at corners — practically invisible, but it extends the sticker's life considerably.
- Narrow bridges in a shape — tearing risk
- Sharp points — lift in use
- Minimum 2 mm corner radius
- Very complex contours increase cutting time
Kiss-cut or full cut — which when
In kiss-cut mode the blade cuts only the top, printed layer and the backing stays intact — stickers remain on a sheet and peel off individually. This is ideal when stickers are handed over as a set (a sticker pack, an insert in an order parcel, event material). With a full cut each sticker is a separate piece — better when stickers are used one at a time or applied in different places. Kiss-cut has an extra advantage: the sticker stays protected on its backing and is easier to store.
Cutting modes and their uses
| Mode | What it cuts | Result | When to choose |
|---|---|---|---|
| Kiss-cut | Top layer only | Stickers on a sheet | Sets, sticker packs |
| Full cut | The whole material | Individual stickers | One-at-a-time use |
| Round / oval | Standard contour | Clean edge | Product labels |
| Logo silhouette | Vector contour | Brand shape | Maximum visibility |
| Rounded rectangle | Straight lines + radius | Durable edge | Most practical option |
How It Works
- 1
Define the contour
We agree the shape the sticker should be cut to — logo silhouette, round, or something else.
- 2
Prepare the artwork
We check for a separate contour layer, bleed and safe area, and create the contour ourselves where needed.
- 3
Printing
Printing runs on the chosen material in CMYK, bleed included.
- 4
Lamination (where needed)
Protective film is applied before cutting so the edge is sealed too.
- 5
Plotter cutting
The plotter follows the contour in the chosen mode — kiss-cut or full cut.
Frequently Asked Questions
I have no contour line — is that a problem?
How complex can the shape be?
How is a sticker pack made?
How is a round sticker's size defined?
What is the cutting tolerance?
How much does die-cutting add to the price?
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