Tips for Clean Cuts and Fabric Prep Using Die Cuts

Have you ever spent an entire Sunday afternoon battling a rotary cutter, a slipping acrylic ruler, a dull blade, and a sore wrist, only to end up with imperfect squares? It’s a frustrating scenario that most seasoned quilters and sewers are familiar with.

Fortunately, modern sewing technology has gifted us the die-cut machine. It is essentially a cookie cutter for your quilt blocks, and it changes the game entirely. However, to get those pristine, sharp edges that make piecing a dream, you have to learn the process. You cannot just shove a wrinkled fat quarter into the machine and expect perfection.

We are going to walk through tips that will help you prep your fabric and get clean cuts using die cuts.

What Is Die-Cutting?

Die-cutting is a manufacturing process adapted for the home sewist. It uses a steel blade embedded in foam, paired with a machine that applies even pressure to slice through multiple fabric layers. Unlike rotary cutters, die cuts deliver perfect dimensions every time. However, for the best results, you must prepare the fabric and use the machine properly.

How To Prep Fabric for Clean Cuts

You wouldn’t try to sew a dress without checking your pattern size, and you shouldn’t try to die-cut without prepping your textiles. Take a few minutes to prepare your material with the following steps.

Press Your Fabric Flat

Wrinkles, folds, creases, and pleats create extra fabric volume that distorts the shape as it passes through the rollers. If you cut over a crease, you will end up with a jagged edge or a piece that is slightly larger than intended once it is unfolded.

So make sure to press your yardage thoroughly. Use steam if your fiber content allows it, but make sure the fabric is cool and dry before you bring it to the die. A hot, damp fabric can distort as you handle it. You want the material to be as flat and dry as a sheet of paper.

Use Starch

Fabric shifts and stretches. By applying a heavy coat of starch or a starch alternative (like Best Press or Flatter), you temporarily change the hand of the fabric.

Stiff fabric behaves like cardstock. It goes through the cutter without shifting, the blades slice through it cleanly, the fibers don’t fray, and the pieces stack neatly. Moreover, starched pieces feed into your sewing machine much more easily later on.

Rough Cut to Size

Don’t try to run a full yard of fabric through the machine if the die is only 6 inches wide. It is unwieldy and wasteful. Instead, perform a rough cut. Measure the shape of the die blades (the rubbery part), add about half an inch on all sides for safety, and use your rotary cutter or scissors to cut a manageable chunk of fabric.

This accomplishes several things: it saves fabric, makes loading the machine easier, keeps the grain straight, and prevents accidental cuts on the excess yardage.

Tips for Using a Die-Cut Machine Properly

Now that you’ve done the fabric prep, it’s time to use your die-cut machine. Here are some tips to get clean cuts.

Don’t Overload the Layers

If you stack too many layers onto the die cut, the fabric on the bottom might cut perfectly, but the layers on top might shift and end up slightly different sizes.

Typically, the max you can safely cut is six layers of cotton at a time. If you are cutting thicker materials like wool, flannel, denim, or batting, even fewer layers are better.

Pro Tip

Listen to your machine. If you have to force the handle or the motor sounds like it is dying, you have too many layers. Remove a few and try again.

Follow the Grainline

Fabric has a grain, which is the direction the threads are woven. The straight grain (parallel to the selvage) has very little stretch. The crosswise grain has a bit more give. The bias (at a 45-degree angle between the straight and crosswise grain) is the stretchiest.

When you load your fabric onto a die, you must align the grain properly. Ideally, you want the lengthwise grain to run parallel to the roller’s movement. This prevents the machine’s pressure from stretching the fabric as it pulls it through. If you ignore the grain, you might end up with distorted shapes that don’t fit together when you try to piece them.

Angle the Die

When you feed the die into the machine, try to angle it slightly rather than sending it in perfectly straight. This helps the roller climb onto the plastic mat more easily.

Rotate Your Cutting Mats

Every time you roll the cutting mat through the machine, the steel blades scar the plastic. Eventually, these grooves can become deep enough that the mat creates a track. If you always cut in the exact same spot, the mat will warp and affect cut quality.

Extend the life of your mats by rotating them every time. Flip them over, spin them around, use the left side, and use the right side. Distributing the wear evenly keeps the mat flat, which creates better pressure and cleaner cuts.

Keep the Machine Clean

Fabric creates lint. Cutting fabric creates a lot of lint. Over time, these tiny fibers can build up in the gears and rollers of your machine.

Every so often, use a soft brush or canned air to blow out any debris from your machine. This keeps the device running longer, and it keeps your dies clean.

Get Die-Cutting Supplies at Inspired To Sew

If you are ready to retire your rotary cutter for the heavy lifting and embrace the world of perfect geometric shapes, we have exactly what you need. At Inspired To Sew, we carry a comprehensive collection of AccuQuilt fabric dies and related products designed to elevate your quilting game.

Whether you are looking for specific geometric shape dies, the popular Block on Board (BOB) dies, strip cutters, or intricate appliqué dies, our inventory is stocked to spark and support your creativity. We also offer the cutting mats and machines required to get started. Browse the AccuQuilt collection today!