If you are new to hot foil stamping, you may hear several different names for the same piece of tooling. Foil die, foil block, foil plate and foiling die are all interchangeable terms. Although they have different names, they all refer to the same basic thing: the engraved plate that is heated and pressed onto the material to transfer the foil.

The right die depends on your press, the detail in your artwork, the material you are stamping and the length of your production run.

What Does “Gauge” Mean?

Gauge simply refers to the thickness of the die.

Common foil die thicknesses include:

• 1.63 mm (16 gauge) – commonly used on label machines and smaller hand or semi-automatic presses.
• 4 mm (8 gauge) – often used on hand-operated and semi-automatic vertical presses.
• 6.35 mm (¼ inch gauge) – commonly used on UK and USA type-height machines and many clamshell, cylinder and automatic presses. (Also 23.3 mm type-height machines)
• 7 mm – commonly used on European and many Asian and other international machines. (Also 23.5 mm type-height machines)

The important thing to understand is that the gauge you need depends on the type height of your press.

Traditional UK/USA machines generally work around a 23.3 mm type height, while European and many international machines use approximately 23.5 mm. This is why 6.35 mm (23.3 mm type height) and 7 mm (23.5 mm type height) dies are so common. The thickness of the die works together with the machine's heater plate and other mounting components to achieve the correct overall height.

What Gauge Is Right for Your Machine?

Die thickness	Common use
1.63 mm / 16 gauge	Label machines, small presses and short-run applications
4 mm / 8 gauge	Hand presses and semi-automatic vertical presses
6.35 mm / ¼ inch	UK/USA type-height clamshell, cylinder and automatic presses
7 mm	European, Asian and other international type-height machines

 

For a top press or vertical press where the impression is controlled by the press mechanism rather than a fixed type height, you may have more flexibility with die thickness. In these machines, different gauges can often be used depending on how the die is mounted and how the press is set up.

However, this does not mean any thickness can automatically be used on any machine. Always check the press manufacturer's specifications and mounting system before choosing a gauge.

If you are unsure, simply tell us which machine you have, and we can advise you on the appropriate gauge.

Types of Foiling Dies

There are several materials used to make foil dies. Each has its own advantages and is suited to different applications.

1. Brass Dies – The Best All Round Choice

If you want a foil die that combines quality, durability, sharp detail and long-term reliability, brass is hard to beat.

Brass dies are manufactured using CNC engraving. A computer-controlled machine precisely cuts the artwork into a high-grade brass plate. This gives the die extremely sharp edges and excellent definition.

Brass is available in different gauges, including:

• 1.63 mm (16 gauge)
• 6.35 mm (¼ inch gauge)
• 7 mm
• 10 mm

Best for

• Medium to long production runs
• Fine and detailed artwork
• Logos and branding
• High-quality foil stamping
• Leather stamping
• Debossing and embossing
• Combination foil and embossing
• Dies that need to be stored and reused
• Premium finishing work

Advantages

• Extremely sharp, high-definition detail
• Excellent durability
• Excellent heat transfer
• Suitable for medium to long runs
• Can be CNC engraved to greater depths
• Suitable for embossing and debossing
• Does not corrode like magnesium
• Excellent for long-term storage
• Can be reused for future production
• Consistent results over a long working life

One of the biggest advantages of brass is that it can be machined rather than chemically etched. This gives much greater control over the shape and depth of the engraving and allows more complex finishes to be produced. Brass can also be machined to deeper levels where required, making it particularly useful for embossing and debossing.

For a professional die that you want to keep, reuse and rely on for years, brass is the ultimate choice.

The downside?

The main disadvantage is the initial cost. Brass generally costs more than a standard magnesium die.

However, if the die is going to be used repeatedly, the extra investment can be worthwhile because of its long working life, durability and ability to be stored and reused.

2. CNC - Engraved Magnesium Dies – Fast and Affordable

CNC-engraved magnesium gives you an excellent middle ground between a basic etched die and a premium brass die.

Instead of using a chemical etching process, the artwork is machined directly into the magnesium using CNC equipment.

This makes CNC magnesium particularly useful when you need a die that is inexpensive and quick to produce, while still wanting good definition.

Best for

• Short to medium runs
• General foil stamping
• Logos
• Text
• Less complicated artwork
• Jobs requiring a quick turnaround
• Customers looking for a more affordable alternative to brass

Advantages

• Inexpensive
• Quick to produce
• Good definition
• Lightweight
• Suitable for many foil stamping applications
• A good alternative when brass is not required

Disadvantages

• Not as durable as brass
• Not ideal for very long production runs
• More susceptible to corrosion
• Not the best option for extremely fine or complex artwork
• Less suitable for long-term storage than brass

CNC magnesium is a particularly good choice when speed and price are important, but you still want a professionally machined die.

3. Chemically Etched Magnesium Dies

Chemically etched magnesium is a traditional method of producing foil dies. The artwork is transferred onto the magnesium and the exposed areas are chemically etched away.

It is commonly used for straightforward artwork and shorter production runs.

Best for

• Short runs
• Simple logos
• Larger lettering
• General foil stamping
• Jobs where extremely fine detail is not required

Advantages

• Can be economical in some markets
• Quick production
• Lightweight
• Suitable for straightforward artwork

Disadvantages

• Less precise than CNC engraving
• Expensive to buy locally
• Limited when very fine detail is required
• Shorter working life than brass
• Can corrode if not stored correctly
• Chemical etching can limit the shape and depth of the engraving

Important: chemically etched magnesium is not necessarily the cheapest option everywhere. In some local markets, the manufacturing process can make chemically etched dies surprisingly expensive.

For this reason, CNC-engraved magnesium locally can be a very attractive alternative, particularly when you want a quick and competitively priced die.

4. Copper Dies – Excellent for Extremely Fine Detail

Copper is a hard and durable material that is particularly well suited to very fine and complicated artwork.

Copper dies are commonly produced using UV and chemical etching processes and can reproduce extremely fine lines, small text and intricate designs.

Best for

• Extremely fine artwork
• Small text
• Very thin lines
• Complicated designs
• Overlapping lines
• Long production runs

Advantages

• Excellent fine-detail reproduction
• Very durable
• Good heat conductivity
• Suitable for long runs

Disadvantages

• Can be expensive
• Chemically etched copper can be costly to produce
• Less flexible than CNC brass for certain specialist applications

Copper is an excellent specialist material, but for many customers, CNC brass offers a better balance of detail, durability, versatility and cost.

5. Zinc Dies

Zinc has traditionally been used for printing and stamping plates and can also be used for foil stamping. It is a relatively soft metal, which makes it easy to machine or etch, but this also means it is less durable than harder materials such as brass and copper.

Best for

• Simple artwork
• General stamping
• Short to medium runs
• Older or specialised equipment

Advantages

• Relatively economical
• Suitable for straightforward artwork
• Easy to produce

Disadvantages

• Less durable than brass
• Not ideal for very fine detail
• Less commonly used for modern foil stamping

For most modern professional applications, brass or magnesium will generally be a more practical choice.

6. Polymer Plates

Polymer plates are made from a photopolymer material rather than metal. They are lightweight and can be an economical option for certain applications.

Best for

• Short runs
• Craft applications
• Simple artwork
• Small presses
• Lightweight stamping applications

Advantages

• Lightweight
• Inexpensive
• Quick to produce
• Easy to handle

Disadvantages

• Less durable than metal
• Not ideal for long runs
• Less suitable for heavy pressure
• Limited compared with brass for detailed or demanding applications

Which Die Should You Choose?

As a simple guide:

Die type	Best for	Main advantage	Main disadvantage
CNC Brass	Medium–long runs and detailed work	Best combination of detail, durability and versatility	Higher initial cost
CNC Magnesium	Short–medium runs	Fast and inexpensive	Less durable than brass
Chemically Etched Magnesium	Short runs and simple artwork	Traditional and relatively quick process	Detail and cost can vary
Copper	Extremely fine detail and long runs	Excellent fine detail	Can be expensive
Zinc	Simple/general work	Economical	Less common and less durable
Polymer	Short runs/light applications	Lightweight and inexpensive	Limited durability

Why Choose Brass?

For professional press work, brass remains the premium choice.

A CNC-engraved brass die gives you the combination of:

Sharp detail + durability + excellent heat transfer + long working life + reusability.

It is particularly useful when you need a die that can produce the same quality impression over and over again.

Because brass does not have the same corrosion concerns as magnesium, it is also an excellent material for storing dies for future jobs. A customer can have a brass die made today and potentially bring it back into production years later.

Brass can also be CNC machined to different depths and profiles, making it suitable for more than simple foil stamping. It can be used for debossing, embossing, leather stamping and combination foil/embossing work.

Brass & Press

At Brass & Press, we specialise in CNC-engraved brass foil dies at a competitive price.

We manufacture brass dies in different gauges to suit a variety of presses and machines, including international and Asian machines where 7 mm dies are commonly required.

We also offer:

• CNC-engraved magnesium dies – inexpensive and quick to produce
• 6.35 mm CNC-engraved magnesium dies
• Chemically etched magnesium dies
• Polymer plates (Coming Soon)

If you are unsure which material or gauge is right for your machine, simply send us the make and model of your press and we can help you choose the right option.

To enquire about a foil die or get a quote, send us an email with your artwork and press details.