Dielines, Bleeds, and CAD Basics
Construct dielines for boxes, labels, and forms. Cut/fold/glue, bleed, safety zones. How CAD drawings translate to tooling.
Executive Summary
This module provides the authoritative technical basis designers and engineers need to construct dielines for folding cartons, corrugated boxes, and labels; to set bleeds, safety zones, and quiet zones; and to understand how CAD drawings become cutting/creasing tools.
Key Insights
- Dielines must be explicitly tagged as non-printing "processing steps" (cut, crease, perf, glue, varnish, etc.) using ISO 19593-1 standards
- Bleed and safety zones are process-dependent, not universal - use ≥3mm as minimum default, then confirm per converter spec
- ECMA & FEFCO codes accelerate structural choices and vendor alignment
- Barcodes drive keep-away and print/die registration budgets - follow GS1 specifications
- PDF/X for handoff + Processing Steps for finishing is the current best-practice stack
- Toolmaking realities impose tolerances that must reflect in safety zones and trap plans
- Regulatory & sustainability shifts will impact artwork real estate - plan for EU PPWR and UK EPR requirements
Recommended Actions
- Standardize packaging PDF handoffs with PDF/X-4 and ISO 19593-1 Processing Steps layers
- Adopt default geometry budgets: 3mm bleed minimum, ≥3mm text/logo safety from knives
- Pin barcode specs in the dieline with X-dimension, magnification, and target ISO grade
- Reference ECMA/FEFCO style libraries for structural choices
- Document recyclability labels & claims early, reserving space for compliance marks
Definitions & Concepts
Dieline
Vector path set that defines cut, crease/score, perforation, glue areas, holes, windows, and non-printing technical features. In PDF, these should be on Processing Steps layers with spot colors.
Bleed
Artwork extension beyond the final trim/cut to avoid white slivers from cutting tolerances; commonly ≥3mm for packaging.
Safety Zone
Minimum distance from trim/knife/score within which critical text/symbols should not appear (often ≥2-3mm for labels; ≥3mm cartons).
Quiet Zone
Mandatory blank area around a barcode, defined by GS1 as a multiple of module width (X-dimension).
Processing Steps
Standardized method to tag finishing steps in PDF (cut, crease, varnish, glue, braille, legends) per ISO 19593-1.
ECMA/FEFCO
European style libraries for folding cartons (ECMA) and corrugated (FEFCO) - use for structural selection and RFQs.
Standards & Regulations
Key Standards
- • ISO 19593-1: Processing Steps for packaging & labels
- • PDF/X (ISO 15930): Constrained, predictable print PDFs
- • ISO/IEC 15416: Linear barcode quality (2025 edition)
- • ISO/IEC 15415: 2D barcode quality (2024 edition)
- • ECMA/FEFCO: Structural style codes for cartons and corrugated
Regional Highlights
EU: PPWR (Regulation (EU) 2025/40) entered into force 11 Feb 2025; general application 12 Aug 2026
UK: EPR data reporting and eco-modulated fees ramping; OPRL labelling adoption timelines
US: No federal EPR; recyclability claims governed by FTC Green Guides (update pending)
Design Rules & Benchmarks
Common Bleed & Safety Defaults
| Application | Outer Bleed (min) | Text/Logo Safety | Notes |
|---|---|---|---|
| Folding cartons (litho) | 3.2mm (0.125") | ≥3mm | Glue flaps up to 6.35mm (0.25") bleed |
| Pressure-sensitive labels | 3mm | ≥2-3mm | 3mm text-free area common |
| Shrink sleeves | 3-5mm | ≥3-5mm | 2mm clear at top/bottom bands typical |
Rules of Thumb
- Bleed: Use ≥3mm everywhere; ≥6.35mm over glue-flap seams where requested
- Safety zones: ≥3mm for cartons; ≥2-3mm for labels; larger around folds/perfs
- Processing steps: Place CUT/CREASE/PERF/GLUE/BRAILLE/LEGEND as ISO 19593-1 Processing Steps
- Barcode keep-away: Reserve GS1 quiet zones and keep bar height intact
- Trapping: Set by process & house curves; typical traps increase from offset (smaller) to flexo (larger)
Common Pitfalls & Red Flags
- Dieline on CMYK or set to "print" - should be a non-printing Processing Step
- Missing BleedBox/TrimBox in PDF handoff
- Text/logos inside 2-3mm of knives; barcode in a seam/near score
- Ignoring quiet zones or insufficient bar height
- Varnish/foil over glue areas; untagged coatings
- No legend for line styles/colors; vendor guesses processing intent
- Failing to specify style code (ECMA/FEFCO) in RFQ
- Under-estimating die-cut tolerances; art hugs edges
- No space budgeted for recyclability labels (OPRL/How2Recycle)
- Inadequate barcode grade targets in specs
Case Studies
Case 1: White Slivers After Die-Cut
Problem: Carton edges show white slivers after die-cut.
Solution: Increased bleed to 3.2mm globally; 6.35mm over glue flaps; ensured ISO 19593-1 CUT/CREASE tagged correctly.
Result: White slivers eliminated; make-ready reduced.
Case 2: DataMatrix on Curved Label Failed
Problem: DataMatrix on a curved beverage label failed in-market scans.
Solution: Re-sized symbol to meet module size and quiet-zone needs; moved away from seam; targeted ≥C grade under ISO/IEC 15415.
Result: Verification passed; readability restored.
Case 3: IML Label Text Clipped
Problem: IML label text clipped post-cut due to print-to-cut shift.
Solution: Enforced 3mm text-safe area; added control targets; revised dieline Processing Steps.
Result: No text clipping across three runs.
Key References
- • ISO 19593-1:2018 - Processing steps for packaging and labels
- • Ghent Workgroup (GWG) - Packaging specifications
- • ISO 15930 - PDF/X series
- • ISO/IEC 15416:2025 - Linear barcode quality
- • ISO/IEC 15415:2024 - 2D barcode quality
- • ECMA - Folding carton design styles
- • FEFCO - Corrugated styles
- • GS1 General Specifications - Barcode standards