Using Die-Cut in AI-Estimator
Overview
AI-Estimator now includes flexible and scalable die-cut support, allowing accurate setup, costing, and estimation for all die-cut operations.
This enhancement supports both Die-Cut as a Category (when the die defines the product’s geometry) and Die-Cut as a Step. Below is an overview of how the feature works and how to use it.
Die-Cut as a Step
When a product’s overall shape remains standard — such as a leaflet, flyer, or card — but a die is used as a finishing process, configure it as Die-Cut Step.
When to Use
The die only enhances the product visually or functionally (e.g., window cut, rounded corners, perforation).
The product retains a standard rectangular layout.
How It Works
In the Product setup sheet, create an add-on step under
PriceModel2with the step codedie_cutting.You can define this in a different Price Model if preferred, but
PriceModel2is the recommended configuration.
In your Product tab, include
die_cuttingas one of the production steps for the relevant product type.When estimating, the user (or AI agent) can add
die_cuttingmanually as a post-press step.
Costing Model Example
Finishing Step | Code | Cost Basis | Setup (hrs) | Run Speed (units/hr) | Labor Rate | Machine Rate |
Die Cutting |
| Per Copy | 0.5 | 1500 | €65 | €25 |
Product | Added Step | Sheets | Total Cost |
Leaflet (A4) |
| 1,000 | €105 |
Total Cost=(Setup Hours+Run SpeedSheets)×(Labor Rate+Machine Rate)
(0.5+1000/1500)×(65+25)=(1.1667)×90=€105
This setup allows die-cutting to be reused across any product type with consistent costing logic.
Die-Cut as a Category
When the die defines the product geometry, such as folders, door hangers, or tags, use Die-Cut as a Category. This approach automatically handles flat-size calculation, imposition, and costing.
Video guide: How to define a die-cut category
When to Use
The product’s shape or layout is determined by the die.
You need to calculate flat size and sheet usage before printing.
How to Configure
In the Product setup sheet, go to the
DieCutMakeuptab and define your Die-Cut product templates.In the PriceModel2 tab, set up the
die_cuttingstep for costing (if not already done).In the Die Cut tab, add
die_cuttingto the list of Production Steps.In the Category tab, set the Category Type to Die Cut.
Formula-Driven Flat Size
Each die-cut product template calculates its flat size dynamically based on the finished size.
Category | DieCutProductName | Formula_FlatWidth | Formula_FlatHeight | MinWidth | MaxWidth | MinHeight | MaxHeight |
Die-Cut | Folder_TwoPocket |
|
| 100 | 350 | 150 | 500 |
Die-Cut | DoorHanger |
|
| 50 | 150 | 100 | 350 |
Die-Cut | BusinessCard_Rounded |
|
| 40 | 100 | 20 | 70 |
In Practice
When a Die-Cut product is selected on the Create Estimate page:
The system displays the available product templates from your
DieCutMakeupconfiguration.The user (or AI agent) selects the appropriate template (e.g., 9x12 Pocket Folder).
The system converts the product to flat size for imposition — automatically using paperCalc to determine sheet count, press time, and cost.
Only the relevant printing options (e.g., offset) are shown for die-cut products.