Die-Cutting Force Calculator
Size a die-cutting press from material, thickness and cut length — required force, tonnage and recommended press capacity, with switchable units.
Inputs
Result
Estimates based on shear strength × cut area; blunt tooling, backing and speed raise real force — size a press with margin. Kiss-cut uses similar force over the cut depth. See the Knowledge Base.
How to use itSize a die-cutting press in three steps
- Select the material. It loads a typical shear strength — the resistance the blade must overcome.
- Enter the thickness and the total cut length — the full perimeter of every cut the die makes in one stroke (all knives combined). Switch between mm, cm and m.
- Read the required force and tonnage. The recommended press adds a 25% margin for tool wear, backing and speed.
Why it mattersWhy cut force is worth checking
Die-cutting force scales with the length of the cutting line, not the area of the blank — a small intricate part with a long perimeter can need more tonnage than a large simple one. Undersize the press and it stalls or leaves incomplete cuts; oversize it and you pay for capacity you never use. Estimating the force from shear strength, thickness and cut length is the quickest way to match a job to a machine and to check a new die will run on your existing press.
The mathsThe formula
Tonnage (t) = Force ÷ 9,807
The blade shears through a plane whose area is thickness × cut length, so force is simply shear strength times that area. Worked example: PET at 55 N/mm², 0.4 mm thick, 1,000 mm of cut → 55 × 0.4 × 1,000 = 22,000 N = 22 kN ≈ 2.2 tonnes. Add margin and specify a press of about 2.8 tonnes.
ReferenceTypical shear strength by material
| Material | Shear strength (N/mm²) |
|---|---|
| PET / APET | ~55 |
| PVC (rigid) | ~50 |
| Aluminium foil laminate | ~40 |
| PS / HIPS | ~35 |
| PP | ~30 |
| Paper / carton board | ~15 |
| Corrugated board | ~6 |
Good to knowWhat raises the real force
Blunt or worn rule, a hard cutting plate, high speed, and cutting several layers at once all increase the force needed above the theoretical value — which is why the 25% margin matters. For kiss-cutting (cutting a top layer but not the liner), the force is similar over the cut depth but blade height and pressure control become critical. Match the tooling approach to volume in our tooling cost guide.
FAQFrequently asked questions
How do I calculate die-cutting force?
Multiply the material's shear strength by the shear-plane area, which is the thickness times the total cut length: Force = shear strength (N/mm²) × thickness (mm) × cut length (mm). Divide by 9,807 to convert to metric tonnes.
Does a bigger blank need more force?
Not necessarily — cutting force depends on the total length of the cutting line, not the area of the blank. A small part with a long, intricate perimeter can require more tonnage than a large part with a simple outline.
How much press margin should I allow?
Around 25% above the calculated force is a sensible starting margin. Blunt rule, a hard cutting plate, higher speed and cutting multiple layers all raise the real force above the theoretical value.
What is the difference between through-cutting and kiss-cutting?
Through-cutting severs the whole material; kiss-cutting cuts only the top layer and leaves the liner intact (for labels). The force per unit length is similar over the cut depth, but kiss-cutting needs precise blade-height and pressure control.
What units is cutting force measured in?
Force is in newtons (N) or kilonewtons (kN); press capacity is usually quoted in tonnes (metric tonne-force). 1 tonne-force ≈ 9,807 N ≈ 9.81 kN. This calculator switches between them.