Die-cut Mylar Bags.

The bag is sealed as a normal pouch first, then a steel cutting die trims the outline through the sealed perimeter. That is why the seal areas have to stay straight and continuous, with the shape drawn outside them. Curves are designed around the sealing jaw from the start rather than added afterwards.

The die is a one-off tooling cost and runs again on reorders at no charge.

Sharp internal corners concentrate stress and start tears in the film. Every inside angle on the outline is radiused so the cut edge holds under handling and does not split when the bag is flexed or dropped. A slightly heavier gauge film also holds a cut edge more cleanly.

We check the outline for this before the die is made and will suggest a radius if the artwork has none.

The main cost driver is nesting, meaning how tightly the outlines fit together across the film web. A shape that nests well wastes little material and the unit cost impact is small at volume. An irregular outline with a lot of unusable film between pieces costs more per bag.

The tooling itself is a single charge, not a per-unit one, so the die is amortised over the run.

Design the artwork around the shape rather than cropping a rectangle into it. Keep fine detail and text clear of the cut line, because registration shifts slightly between the printed image and the die. Matte lamination shows the outline without glare along the edge, and gloss catches light on it.

Hot foil can follow the die-cut edge as a border, and a shaped window can echo the outline.

Typical faces run from 4 × 6 inches up to 8 × 12 inches, with the outline fully custom. The face is measured across the widest and tallest points of the shape, and the seal margin is added outside that. If the bag will be filled on an automated line, the feed has to be confirmed before we cut tooling.

Yes, hang features are punched into the shape wherever the peg display needs them. A reinforced hang area adds extra material at that point so the hole does not tear out under the weight of a full bag. Shaped headers and rounded corners are cut in the same pass.

All the standard barrier laminates, from metallised to foil to kraft, cut cleanly, so the outline never limits the structure.

Shaped pouches start at 500 units per design. Because the die is a fixed cost, the per-unit share of tooling falls as the run grows, and pricing tiers again above 1,000. Reorders reuse the same die, and dieline preparation is done free of charge.

Production takes 7 to 10 business days once the die is approved, and a rush option runs 5 to 7 business days. A sample in 5 to 7 business days shows the cut edge, the corner radii and the seal integrity on the real film.

Whatever you pay for the sample is credited to the production order, and shipping is nationwide across the USA.