Die cut through all layers versus kiss cut to the liner

# Die cut vs kiss cut: what changes, and the cost > Die cutting separates each sticker; kiss cutting leaves it on the sheet. How each is produced, when a die pays for itself, and the artwork each needs. Pillar: sticker-materials · Updated: 2026-11 **Our view.** At 50 units we steer customers towards kiss-cut sheets, because a custom die can double the price of a first order and the shape is rarely the thing being tested. Move to individual die cuts once the design is proven and the quantity justifies the tooling — which is usually somewhere around a few hundred pieces. The two terms describe where the blade stops, and that single difference decides the format, the handling and often the price. ## The mechanical difference

Die cutting goes through the liner; kiss cutting stops at it.

**Die cut**: the blade cuts through the sticker, the adhesive and the backing. Each sticker comes out as an individual piece. **Kiss cut**: the blade cuts through the sticker and the adhesive but stops at the backing paper. The stickers stay on the sheet and are peeled off one at a time. Neither is a quality difference. They are different products for different uses. ## When die cut is right - Stickers handed out individually: events, samples, retail. - Stickers applied by hand or by an applicator onto a product. - Shapes that should have no visible border (contour cut). - Large stickers, where a sheet would be unwieldy. Die cutting a custom shape needs a cutting path. At low volume this is done on a plotter (no die cost); above a few hundred units, a steel rule die is made and the per-piece cost drops sharply. ## When kiss cut is right - Sets of small stickers on one sheet, sold or given as a pack. - Ecommerce inserts with several designs. - Stickers under about 20 mm, which are awkward to peel individually. - Designs where the sheet itself is part of the product. Kiss cutting is cheaper per sticker at low volume because there is one cutting pass for the whole layout rather than one per piece. ## The cost curve | Quantity | Sensible method | Why | |---|---|---| | 50–300 | Digital contour cut or kiss cut | No die cost | | 300–2,000 | Steel rule die | Die amortises quickly | | 2,000+ | Die + roll or sheet | Per-piece cost dominates | A custom die is a one-off cost. At 50 units it can double the price; at 5,000 it is rounding error. ## Artwork requirements Both methods need a **closed vector cut path** on a separate layer. Differences: - Die cut needs 2 mm bleed beyond the cut line, and features at least 1.5 mm wide. - Kiss cut needs at least 3 mm between neighbouring cut paths so the blade does not tear the sheet. - Contour cuts should follow the outer shape; cutting every internal counter produces fragile pieces. ## What this means for buyers **Choose the format from the use, not the price.** A sheet of six small stickers is the right product for an insert; individual die cuts are right for hand-outs. **Do not pay for a die at 50 units.** A simple shape or a kiss-cut sheet avoids it. **Complex outlines cost more than they look.** Thin spikes and letter-shaped cut-outs tear when peeled; simplify the path. **Both need a vector cut path.** If you only have a flat image, expect a small setup charge for someone to draw the path. ## Quick answers **What is the difference between die cut and kiss cut?** Die cutting cuts through the sticker, the adhesive and the backing, so each piece comes off individually. Kiss cutting cuts the sticker and adhesive but stops at the liner, so the stickers stay on the sheet and are peeled one at a time. **Which is cheaper for a small order?** Kiss cut, at low volume. It needs no steel die and one cutting pass covers the whole sheet. A custom die adds a one-off cost that dominates at 50 units and becomes negligible only once the run is in the thousands.