Sticker Cutline Design for Graphtec Machines – Requirements & Best Practices

2025-10-13 • cutline design, Graphtec, sticker printing, prepress

Creating accurate sticker cutlines for Graphtec cutters is a vital part of prepress production. A small setup mistake — such as the wrong spot color or missing alignment mark — can waste an entire sheet of prints. Here’s a step-by-step guide to designing precise, machine-ready cutlines for Graphtec plotters.

1. Software & file format

You can create cutlines in vector-based software such as Adobe Illustrator or CorelDRAW. Graphtec’s Cutting Master plugin integrates directly with Illustrator and Corel to send jobs to the cutter.

Recommended file type: PDF or EPS (vector format)
Color mode: CMYK for print layers; Spot Color for cutlines
Resolution: 300 DPI for embedded images

2. Cutline spot color setup

Create a spot color swatch named exactly CutContour or CuttingMaster_CutLine (depending on your Graphtec software version).

Set it as a stroke only (no fill)
Stroke weight: 0.25–1 pt
Place it on a separate top layer named Cut Lines
Avoid duplicate paths or grouped masks around the contour

3. Registration mark setup

Registration marks help the cutter align precisely with your printed design. Cutting Master or Graphtec Studio can automatically add marks compatible with your device model.

Use the correct mark type (Type 1, Type 2, etc.) for your cutter
Keep marks at least 10 mm away from sticker edges
Ensure all marks are printed in black (100K) only

4. Design considerations for clean cuts

Use smooth bezier curves — avoid sharp spikes or rough edges
Round corners slightly (0.3–0.5 mm radius) to prevent blade lifting
Group artwork with its cutline before exporting
Always include at least 2 mm bleed beyond the cutline

5. Export & test

Export your print-and-cut file as PDF (Illustrator preset: PDF/X-4) with the spot color intact. Open it in Graphtec’s Cutting Master and test a small sample first to confirm cut alignment and pressure settings.

6. Common issues & fixes

Cut not detected? Check if your spot color is set to “Spot” type, not CMYK.
Cut misaligned? Recalibrate optical mark sensor or reprint with proper margins.
Uneven cut depth? Adjust blade extension (recommended: 0.3 mm visible tip).

Pro tip: Keep your cut paths simple. Overly detailed outlines can slow down the cutter and cause mechanical wear.

At PrintReadyFile.com, we prepare thousands of cut-ready sticker files for Roland and Graphtec devices — optimized for speed, accuracy, and flawless cut registration. Whether you need single jobs or bulk outsourcing, our prepress services can handle it.