Cone Sleeves

Custom Die-Cut Sleeves

Everything else in this range starts from a known shape. This page is for the jobs that do not — a sleeve with a window, a contoured top edge, an unusual product profile, or a shape nobody has cut before.

A bespoke die costs more up front and then costs nothing extra per unit, which changes how you should think about the quantity.

Get a quote WhatsApp us

Cut to your own product, not a stock size
Board, print and finish confirmed in writing
Delivered across the UK on national carriers

Short enquiry

Quote for This Product

Tell us the quantity and any date you are working to. We reply with the board, print and finish, plus the minimum order quantity and lead time.

Design Your Own

Design Your Custom Die-Cut Sleeves

Pick a colour, put your name on it, and see how the idea reads before you ask anyone for a price. It is a sketch rather than a manufacturing proof — the real shape is cut from the product you already serve.

Sleeve colour

Name on the pack

Finish

Show a repeating pattern

Leave two or three centimetres of wafer showing. Customers read a visible cone as freshly made, and the sleeve still catches the first drips.

Carry this into the full designer

The full page adds the size, board, print and quantity, then sends the whole specification over in one go. Nothing is committed to at any point.

The Die Is a One-Off, Not a Per-Unit Cost

A die is a physical cutting form. It is made once, paid for once, and used for every reorder afterwards.

That means the die cost spreads across everything you ever print from it. On a first order of a few thousand it looks expensive; across three years of reorders it usually is not.

Shapes Worth a Bespoke Die

A window that shows the product through the sleeve.
A contoured top edge that follows the shape of what it wraps.
A locking tab so the sleeve holds without glue.
A profile matching a product that no standard sleeve fits.
A hanging or display feature for retail rather than counter sale.

Anything that can be drawn as a closed outline can generally be cut, within limits on very fine detail.

How a Bespoke Die Job Runs

Describe the Shape and the Product
A sketch and the product's dimensions are enough to start. A physical sample is better.
We Produce a Die Line
A drawing showing cut, crease, overlap and safe area, which your designer works onto.
Check a Plain Cut Sample
An unprinted sample cut on the die, wrapped around the real product. Changes are cheapest here.
Print from the Approved Die
Once the shape is signed off the artwork is placed and the run scheduled.

Our what we need in an artwork file covers the file formats and layers that make this stage quick.

Ordering, Artwork and Delivery

Getting a Quote

Send us two or three of the cones you use, or the top diameter and slant height. We reply with a written specification, the minimum order quantity and the lead time for your job.

Artwork

We supply a die template cut to your cone before design work starts. Full file requirements are set out in our artwork guidelines.

Turnaround

Lead times depend on the print method, run length and press schedule, so we confirm yours on the quote rather than publishing a single figure.

Delivery in the UK

Orders are dispatched on national carriers to any UK address. Seedelivery information for how dates are given.

Custom Die-Cut Sleeves: Common Questions

Do we own the die once it is made?

Ownership, storage and reuse terms are set out on your quote. It is a fair question to ask before committing, and we would rather put it in writing than leave it assumed.

Can a window be cut without adding film behind it?

Yes — an open cut-out with no film is common and avoids a mixed material. The trade-off is that the product is exposed at that point, which suits a wrapped item and not a loose one.

How small can cut detail be?

Fine detail is limited by the board thickness — a thick board cannot hold a sharp small feature cleanly. Send the shape and we will tell you what will and will not cut before you commit.

How long does a new die take to make?

It is a separate step ahead of printing, and its lead time is confirmed with your quote. A first order needing a new die always runs longer than a reorder from the same die.

Can you cut any shape?

Anything that can be drawn as a closed outline, within limits on very fine detail. Board thickness sets how sharp a small feature can be, and we will tell you before you commit.

Do we need to supply a technical drawing?

No. A sketch and the product's dimensions are enough to start, and a physical sample is better still. We produce the die line from that.

Can we see the shape before printing?

Yes, as an unprinted sample cut on the die. Wrapping that around the real product is the cheapest possible moment to change anything.

Is a window cheaper without film?

Yes, and it avoids a mixed material. The trade-off is that the product is exposed at that point, which suits a wrapped item more than a loose one.

Can the die include a locking tab?

Yes, and it removes the need for glue on some formats. It has to be designed into the shape rather than added later, so raise it early.

What happens to the die between orders?

Storage and reuse terms are set out on your quote. It is a fair question to ask before committing, and we would rather put it in writing than leave it assumed.

Prefer to Talk It Through?

Sizing questions are usually quicker on the phone, especially if you have the product in front of you.

+44 7458 651107 info@conesleeves.co.uk