Die cut hang tags let a cardboard tag take a shape other than a plain rectangle – rounded corners, clipped luggage-tag corners, a circle, an oval or an outline that echoes your logo. Shape registers before colour or text: on a crowded rail, the silhouette of the tag is the first thing the eye picks out. This article covers a glossary of standard shapes, how a cutting die is made, when a custom outline is worth the cost, and the rules that keep your design safe when it meets the blade.
A glossary of shapes
Rectangle
The most economical shape – sheets are trimmed on a guillotine with no special die. Right for most brands and for first orders. Typical sizes are around 50 × 90 mm portrait or 90 × 50 mm landscape.
Rectangle with rounded corners
A radius of roughly 3–6 mm makes the tag softer and nicer to hold, and the corners don't dog-ear or scratch. It's the cheapest shape upgrade and is often done with a standard die the printer already has.
Luggage tag (clipped corners)
The two top corners are cut at 45° with the hole centred on the top edge. A classic shape with a vintage, workwear feel – much loved by denim and utility brands.
Circle and oval
Round tags of 40–60 mm diameter look like a seal or a medallion. They suit small items – hats, scarves, jewellery, babywear. An oval is more elegant and fits more text.
Square
Modern and minimal, especially with rounded corners. Works well with a centred logo.
Long strip
A narrow portrait tag such as 30 × 120 mm. It looks like a bookmark, has room for a brand story and hangs elegantly along the garment.
Arch and half-circle
The top edge is rounded like an arch – a soft silhouette that suits womenswear and childrenswear.
Custom outline
A tag in the shape of your logo, your product (a shirt, a drop, a leaf) or a brand symbol. The most recognisable option, with the highest up-front cost.
How a cutting die is made
A cutting die is a plywood base with a bent steel rule set into it along the tag's outline. Under pressure the rule cuts the board like a cookie cutter. The same die can also carry:
- A creasing rule – a blunt line for folding booklet-style double tags.
- Perforation – a dotted line for a tear-off stub, such as a size slip or a discount code.
- A hole punch – so the hole is made in the same stroke.
The die is made once for a given shape and size and then stored. On a repeat order the same die is reused at no extra cost.
When a custom shape pays off
| Situation | Recommendation |
|---|---|
| First collection, small run, testing the brand | Rectangle or rounded corners – no extra cost |
| Brand with a clear identity and repeat orders | Your own die – the cost is spread across every future run |
| Seasonal or limited collection | Standard shape in a new colour or finish instead of a new die |
| Product where the tag is part of the gift | A custom outline makes sense even on a smaller run |
The logic is simple: the one-off die cost is divided by the number of tags you'll cut with it over the years. If the shape becomes part of your identity and won't change, it pays for itself quickly.
Design rules for die cut tags
- At least 3 mm bleed beyond the cut line – the background must run past the outline, or a tiny shift will reveal a white edge.
- A 5 mm safe zone inside the outline – keep text, logo and barcode out of it.
- No narrow necks. Parts of the shape narrower than about 3 mm bend and tear. If your logo has thin elements, simplify the outline.
- No razor-sharp inner corners. Steel rule can't form a perfect inside corner; give it at least a 1 mm radius.
- Keep the hole away from the edge. At least 5–6 mm from the nearest edge of the outline, or the tag will tear when pulled.
- Supply the outline on its own layer. Send the cut line as a vector path on a separate layer in a spot colour, not as part of the artwork.
Tip: print the outline at actual size on plain paper, cut it out with scissors and hang it on the garment. You'll see straight away whether the shape reads well or is too fussy.
Matching shape to brand
- Minimalist brand – rectangle or square with a small radius. The shape doesn't compete with the logo.
- Denim, workwear, vintage – luggage tag with clipped corners, kraft board, waxed cord.
- Womenswear and boutique – arch, oval or long strip with a satin tie.
- Childrenswear – circle or rounded square with no sharp corners.
- Brand with a strong graphic mark – an outline following the logo, simplified to a recognisable silhouette.
Shape and the other finishes
Die cutting is the last operation – after printing, lamination, foil and embossing – so the shape has to be planned alongside them. Foil and embossing also need clearance from the outline, and laminating film can lift at the edge of very narrow details. Booklet-style double tags need a crease, or the board will crack when folded. If the tag will have a metal eyelet, leave clear space around the hole – the eyelet takes up more room than the hole itself.
Bul-tex makes custom hang tags in standard and custom shapes – contact us with your outline and size. To attach them, use strings for hang tags, a narrow ribbon, or reinforce the hole with metal eyelets. Read more about hang tags in the Labels section of our blog.
