How to Make Die Cut Mylar Bags: Everything You Need to Know

Thursday, 06 June 2024
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Die cut mylar bags are a famous choice for product packaging due to their flexibility, durability, and ability to preserve the freshness of products. These mylar bags are widely used in various industries, which include:

  • • Electronics
  • • Pharmaceuticals
  • • Food

Creating die cut mylar bags involves several steps, from material selection to the final cutting process, depending on the customer`s or personal preferences. This informative guide will walk you through each creation step in detail.

Understanding Mylar

Before discussing the steps in making die cut mylar bags, let us give a brief overview of Mylar and its various applications.

What is Mylar?

Mylar is a brand name for a type of plastic film known as biaxially-oriented polyethylene terephthalate (BoPET). It is popular among businesses for its durability, strength, and barrier properties against light, moisture, and gases.

Applications of Mylar

Die cut mylar bags are used in electronics packaging, medical supplies, food storage, etc. Their extraordinary capability of ensuring protection against environmental factors makes them perfect for preserving the quality and freshness of various products.

Material Selection

There are two steps involved in the material selection for making die cut mylar bags:

Selection of Right Mylar Film

The type of Mylar file you select depends on the intended use of the die cut mylar bags. The essential factors to consider include barrier properties, thickness, and whether the film needs to be food-grade or meet specific regulatory standards.

Thickness of Mylar Film

Here are some of the standard thicknesses of Mylar film used for making die cut mylar bags:

  • • 2 mil: Lightweight, suitable for short-term storage.
  • • 3.5 mil: medium thickness, provides better durability and barrier protection.
  • • 5 mil: Heavy-duty, excellent for long-term storage and high-barrier requirements

Designing the Die Cut Mylar Bag

To design the die cut mylar bags the right way, you need to work on:

Bag Dimensions: Determine the dimensions of your custom mylar bag based on the size and volume of your product. You can include extra space for sealing and adding additional features, such as tear notches or zippers.

Die Cut Design: The die cut design in the mylar bag involves creating a specific pattern or shape for the bag. It could include unique closure windows of custom shapes. You will require design software to create a precise template for the die cut.

Pre-Production Preparation

For the pre-production preparation, you require:

Prototyping: You must create a prototype of your mylar bag to test the dimensions and design. This essential step helps identify potential issues before moving forward to mass production.

Material Testing: It is necessary to test the Mylar film barrier properties, compatibility with the product, and durability. Make sure it meets all required regulatory standards.

Perform Custom Printing

If you require custom printed die cut mylar bags or branded, you can opt for specialized printing techniques, which include digital or flexographic printing. Moreover, you must ensure that the printing process and ink are compatible with Mylar and don`t affect its barrier properties.

Steps to Follow for Printing

Here are some of the steps you need to follow to perform custom printing on die cut mylar bags:

Design Artwork: You must create the artwork for the die cut mylar bag, including text, logos, and other product or brand-related graphics.

Prepare Printing Plates: To perform flexographic printing, you must prepare printing plates based on your die cut mylar bag design.

Performing Printing: To perform printing, you must use a digital or flexographic printer to transfer your selected design onto the Mylar film.

Die Cutting Process

Before you start the die-cutting process, you require a die, a specialized tool used to cut the Mylar film into your desired shape. The die is typically made from steel and is custom-designed based on your die-cut mylar bag specification. Below are the steps which are involved in the die-cutting process:

Setup the Die-Cutting Machine: You must install the custom die into the die-cutting machine. Afterward, you need to adjust the setting based on the type and thickness of Mylar film.

Feeding the Mylar Film: You need to feed the mylar film into the die-cutting machine. In addition, you need to ensure that the film is correctly assigned to avoid any miscuts.

Cutting the Film: You must activate the die-cutting machine to cut the Mylar film into the desired shape. The die-cutting machine will apply the pressure to the die, cutting through the film precisely.

Quality Control: You need to inspect the die cut mylar bags for consistency and accuracy. In addition, any defective pieces must be removed, and the required adjustments must be made to the die or machine settings.

Sealing and Finishing

The sealing and finishing process of the die cut mylar bags include:

Sealing Options

Here are the sealing options available for die cut mylar bags:

Heat Sealing: You must use a heat seal to close the mylar bags effectively. This method provides an airtight seal, which helps preserve the products` freshness.

Zipper Closures: You can install zipper closures to make resealable die cut mylar bags. This option is convenient for products that need to be accessed multiple times.

Steps of Heat Sealing

Below are the steps of heat sealing:

Set Up the Heat Healer: Adjust the pressure and temperature setting based on the thickness of the Mylar film.

Seal the Bags: Place the open end of the die cut mylar bag between the heat sealer jaws. Afterward, activate the heat sealer to apply pressure and heat, creating a secure seal.

Cooling: After applying the heat seal, let the sealed mylar bags cool and set the seal.

Adding Finishing Touches

Here are the types of finishing touches that you can give to the die cut mylar bags:

Tear Notches: Create tear notches for easy opening.

Hang Holes: Add hang holes for retail display purposes.

Marketing and Sales of Die Cut Mylar Bags

Here is how custom die cut Mylar can help give a boost to your sales and improve your brand marketing:

Product Presentation: You can present your die cut mylar bags professionally to grab the attention of your target audience. In addition, highlight the benefits and features such as customization options, durability, and barrier properties.

Sales Channels: You can promote your custom printed die cut mylar bags via various sales channels, including wholesale distributors and direct sales to businesses and online marketplaces.

Customer Feedback: You can collect customer feedback to improve your services and products. Moreover, you can use this feedback to make the necessary changes to enhance customer satisfaction.

How IMH Packaging Helps in Making Die Cut Mylar Bags

Here is how IMH Packaging helps in making stunning die cut mylar bags:

High-Quality Printing

High-quality printing is vital in the appealing presentation of custom die cut mylar bags. With the help of top-priced inks and modern printing techniques, our designers can create visually stunning packaging that grabs the attention of your target audience. Moreover, it can help you convey your brand message. 

With our modern printing technique, you will be assured that your designs are rendered with extraordinary vibrancy and clarity. This can bring your die cut mylar bags to life.

At IMH Packaging, we offer a wide variety of printing techniques, which include digital printing, flexographic printing, and gravure printing. 

Our professional designers choose it carefully to meet the precise requirements of the product. 

They use outstanding printing inks, enhancing the presentation of your die cut mylar bags.

Availability of Multiple Customization Options

We provide an exclusive range of customization options to empower you to lay out your custom printed die cut mylar bags, which reflect your brand`s identity and beautify your product`s allure. Here are the types of customizations we offer for our die cut mylar bags:

Full-Color Printing

You can unleash your creativity with our full-color printing abilities. We print catchy and colorful designs that show your brand`s identity in style.

Custom Shapes and Sizes

Break free from the norm with our vast range of custom shapes and sizes available in die cut mylar bags. You can get them easily if you need to pack food or any other type of product in such mylar bags.

Matte or Glossy Finish

Make your die cut mylar bags stand out in the competition using our matte or gloss finish, which suits your logo`s personality. Opt for a smooth and sophisticated appearance with a matte finish to grab the attention of your target audience.

Resealable Zippers

Ensure the freshness of the product with the convenience of adding resealable zippers to the die cut mylar bags. This customization option is perfect for products consumers consume over several events.

Tear Notches and Hang Holes

Enhance the functionality of your die cut mylar bags by adding holes for retail display and tear notches for easy beginnings.

Child-Resistant Closures

Keep your product safe from the reach of youngsters by adding child-resistant closures to your custom die cut mylar bags.

Free Design Support

Our team of professional designers is here to remodel your design ideas into eye-catching die cut mylar bags. We work closely to understand your design requirements and use suitable tools to make them. If you don`t know how to design your mylar bags, don`t worry. We have you covered. IMH Packaging offers a free design support service to help you design mylar bags according to the latest printing and packaging trends.

Final Thoughts

Making die cut mylar bags involves a series of well-coordinated steps, from material selection and design to quality assurance and production. By following this detailed guide, you can produce aesthetically pleasing, durable, and high-quality mylar bags which meet your customers` needs. Investing in the right materials, processes, and technology will ensure success in producing durable mylar bags.

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