Laser vs. punch – which is right for your label?

Anyone who produces or orders labels will sooner or later be faced with the question: how should they actually be cut – punched or lasered?
Both methods work and both have their merits, but the differences become apparent when budget, shape, quantity or material come into play

Many people initially think of speed or price. In practice, however, there is much more to it than that:

• Special shapes without tools?
  
• Don't want expensive punching dies?
  
• Clear edges or intricate contours?
  
• Small runs or many varieties?

This is precisely where you decide whether laser or punch makes sense for your project, or whether a combination of both is the best solution.

In the next section, we will look at how both methods work and how they differ technically. After that, it will quickly become clear where their strengths (and limitations) lie.

How lasers and punches work: explained simply

To understand why both methods have advantages and disadvantages depending on the product, let's take a quick look at the technical details.

Punching involves the use of a physical tool: a punching plate with a predefined shape. This tool mechanically cuts the labels out of the material. The process has been tried and tested for years and is particularly efficient when it comes to large quantities and standard formats. The catch: a separate tool is required for each shape, which costs time and money – especially when frequent size or shape changes are required.

Laser cutting works in a completely different way. Here, the work is not done by a tool, but by a digitally controlled laser beam. The contour is cut directly into the material – without set-up times or tooling. This means that new shapes can be implemented immediately, which is particularly advantageous for small runs, many varieties or individual contours. At the same time, there are limitations: for very large runs, the laser is often slower than the classic punch, and depending on the material, heat effects can play a role.

What are the real differences: laser vs. punch comparison

Both processes shape labels – but in very different ways. And this is precisely what results in the typical advantages and disadvantages, depending on what is to be produced:

1. Tool costs

When punching, you need a punching tool. This is particularly worthwhile if the same shape is produced repeatedly – for example, standard labels in large quantities. With laser cutting, these tool costs are completely eliminated because the work is done digitally. Ideal for many variants, changing sizes or special shapes.

2. Flexibility & shapes

The biggest advantage of the laser? Absolute freedom when it comes to contours. Round corners, free forms, fine details – all possible without additional tools. The punch, on the other hand, delivers reliably consistent shapes, but is limited to what the tool specifies.

3. Edge problems & white edges

One point that is often overlooked: how clean is the edge actually? Depending on the material, laser cutting can sometimes leave slight burn marks – especially on plastic labels. The punch cuts mechanically, leaving the edge neutral and without discolouration.

Die-cut shape with typical rotational edge – ideal for high print runs and consistent shapes.

Laser-cut contour – precise, burr-free and without rotational edges.

4. Speed & throughput

The punch shows its strength with large print runs: full production speed, no breaks due to data changes and a single cut per stroke. The laser is more flexible, but slightly slower – however, there is no set-up time.

5. Material & limitations

Not every material reacts equally well to laser energy. Very thick or heat-sensitive materials can be problematic. The punch is less selective – as long as the tool fits, almost anything works.

When is laser the better choice – and when is die cutting?

Whether laser technology or classic die cutting is the better solution depends less on the "principle" and more on the product, the print run and the flexibility you need. Laser punching really comes into its own when shapes need to be variable or small to medium print runs are being produced. Without fixed tools, you can start immediately, implement spontaneous layout changes and even run different shapes in a single job – without any additional costs or waiting times.

The situation is different for series production with consistent shapes: here, the punch scores points for speed and efficiency. If a label remains unchanged for a long period of time and large quantities are produced, the punching tool delivers better performance – both in terms of cost per unit and throughput time. Especially in multi-layer applications or with very special materials, the mechanical punch remains the safest option.

The number of pieces also plays a role in shaping: laser is unbeatable for free forms, inner contours or individual adjustments, without tool adjustments or set-up time. For standard shapes with high volumes, however, punching dies remain more economical once the tool costs have been amortised.

That means: The bottom line is that laser cutting is worthwhile where flexibility is required – for example, with changing varieties, many variants or test quantities. Punching is the right choice when the shape is fixed and large runs are to be produced at high speed.

Comparison of rotary edge vs. laser edge

Our experience & recommendations

We work with both processes on a daily basis – which is precisely why we do not make a blanket decision in favour of laser or punching. Instead, we look at each project individually: material, shape, print run, further processing and time pressure.

What we see time and time again is that many customers start with lasers and then switch to punching tools later on, once the shape has been finalised and production volumes increase. It is precisely this flexibility that is often more important to manufacturers today than the technology itself.

Our conclusion from production: it's not about lasers or punches – it's about the right process at the right time. We combine both so that you don't have to compromise on speed or freedom in terms of shapes or print runs.

Two techniques – one goal

Whether laser or punching is the better choice depends not on the machine, but on your product and the stage of the process. Laser scores highly in terms of flexibility, customised shapes and small to medium runs – without any tooling costs. Punching comes into its own when the shape and quantity are fixed and maximum speed and unit price are key.

The good news is that you don't have to choose. We combine both processes to ensure that you always get the best solution, both technically and economically – from prototype to series production.

If you are unsure which method is right for your label, please contact us – we will be happy to help.