Tobias Reed Production Knowledge Lead at 4OVER4.COM
Tobias is our voice for cutting, binding and large format, built from the knowledge of our production team, with over 20 years in printing.
Question
What is the minimum hole size you can die-cut?
Answer
The smallest hole that can be reliably die-cut is 1/16 inch. Anything smaller risks tearing or inconsistent results.
- Minimum clean hole: 1/16 inch (about 1.6 mm).
- Smaller openings: a thin slit or perforation can sometimes stand in for a very tiny hole.
- Placement: keep holes at least 1/8 inch in from the trim edge so the surrounding material stays strong.
- Not sure it will hold up? Send the file and the team can confirm feasibility before production.
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