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Die-Cut Labels — Any Shape, Made to Spec.
Custom-shape labels rotary die-cut from your dieline — round, oval, contour-following, brand-mark silhouettes and intricate shapes. Every substrate, every finish, every adhesive. Made in Melbourne.
- Any custom shape or size
- Rotary die reused on every reorder
- Premium substrates & finishes
Shape Is Part of the Brand
A die-cut label is cut through the face stock and adhesive to the liner — leaving a label in your custom shape that peels cleanly without a visible rectangular border. The shape itself becomes a brand element: a label that follows the silhouette of a logo, mirrors the curve of a container or traces an intricate decorative outline makes a product instantly more recognisable than anything produced in a standard rectangle. Die-cut labels are available on any substrate and with the full range of finishes, so the premium look of a custom shape does not come at the cost of durability, adhesion or shelf presence. A one-off rotary die is produced to your dieline and reused on every subsequent reorder — meaning the tooling cost is spread across the lifetime of the product, not recharged each time.
Where Die-Cut Labels Make the Difference
Die-cut labels are widely used across premium food and beverage, cosmetics and personal care, spirits and wine, confectionery and gifting, children's products, promotional and seasonal merchandise, and industrial equipment identification. In the beverage category, contour-cut labels that follow the shoulder or base of a bottle create a seamless branded look that rectangular labels cannot achieve. In the personal care and cosmetic category, brand-mark silhouette labels reinforce identity at shelf, particularly when combined with foil or soft-touch lamination finishes. For promotional and campaign use, custom-shape sticker packs and kits with multiple shapes per sheet are a standard deliverable — produced on the same platform with the same substrate and finish options as production-scale die-cut labels.
How Onpack prints die-cut labels
Shorter runs and new-shape launches are produced on Onpack's HP Indigo and L350 digital presses — printed across the full substrate range and then rotary die-cut to your dieline. A custom shape requires a one-off rotary die, which is held on file and reused on every reorder at no additional tooling charge.
Higher-volume die-cut orders run on our UV flexo press with in-line rotary die-cutting — printing, laminating, varnishing and die-cutting in a single pass, which keeps unit costs low on long runs. Hot foil stamping, embossing and high-build tactile varnish are produced on our digital ABG embellishment line, integrated into the workflow before or after die-cutting as the construction requires.
Every die-cut job runs through Onpack's ISO9001 certified processes, with 100% vision camera quality control — ensuring cut register, colour and finish stay consistent from the first label to the last.
A press proof or physical sample is available before your full run, so you can confirm shape, finish and material performance in person before committing to volume.
Ready to Order Die-Cut Labels?
Die-Cut Labels FAQs
A die-cut label is cut all the way through the face stock and adhesive but not through the liner — the label peels cleanly off the liner in your custom shape. A kiss-cut cuts through the face stock only, leaving the label attached to a full sheet of liner for easier hand-separation or sheet-format handling. See the Kiss-Cut Labels page for more detail.
Yes. All die-cutting at Onpack is rotary, so every custom shape requires a die. The die cost is a modest one-off charge — it is then held on file and reused on every reorder, so repeat orders carry no new tooling cost. Standard shapes such as circles, ovals and rectangles can use existing stock dies with no additional charge.
Rotary die-cutting handles a high level of detail. As a practical guide, inside corners should be kept to a minimum of approximately 1 mm radius for a clean, consistent cut. Very fine bridges and hairline cuts are achievable — Onpack’s prepress team will review the dieline and flag anything that needs adjustment before tooling is made.
Yes. Die-cut labels are available on roll, spec’d to your applicator’s core size, wind direction and labels-per-roll count — the same roll specifications as standard rectangular labels.
A high-resolution PDF laid out to your label dimensions — not pre-imposed to sheet. Onpack’s prepress team will impose labels to the correct sheet size, gap and bleed before production. If you have multiple label variants, supply each as a separate file.