Custom Die Cut CD DVD Packaging…
Unique shapes, Knock outs, Lettering, Holes, Windows



Die cuts are some of the neatest things one can do on a project. The possibilities are almost endless. You can make the shape of the packaging a custom shape ( a flower, a cloud, a music note a cross), you can make squigglies and holes, you can knock out letters, you can make a curvy pocket. We'll show you some of the great ideas our clients have had!

  • Custom Die Cut CD DVD Packaging Photos

    custom die cut cd packaging
    custom die cut dvd packaging digipak and slipcase
    custom die cut dvd slipcase with hole cutout
    custom die cut dvd packaging shape knockout
    custom die cut dvd packaging foam hub spinny wheel fiberboard stockcustom die dvd packaging diecut window custom die cut dvd packaging fiberboard stock disc business cardcustom die packaging with cut out shapescustom die cd packaging music curved pocketscustom die dvd packaging book window

    custom die shape cut out cd packagingcustom cut hole dvd pacakging to hold coincustom die packaging windows dvd digipak paper traycustom die cut window cd packagingcustom die cd packaging window for insertcustom die cd packaging box disc and yo yocustom die window cd music packagingcustom die cd jacket pocket notch cutoutdie cut slipcase cd dvd packagingcustom die hole dvd packaging

  • Are custom die cuts expensive?

    At Megalodon, no.
    But in general, yes - very - and you are cautioned against it frequently. Heaven forbid you would want to change the die! When you look at our product photos, you'll notice that there are a huge number of variations in the dies. This is because we encourage dies here - we want you to think outside of the box. To help with that, we subsidize the cost. On a selfish level, we want clients to look at our site and say oh wow, these projects are incredible. Not, oh look, they used catalog/part # 123z. We like to be challenged and to see new and interesting things so please, do be creative!
    custom die cut cd packaging lettering knockout

    Here's the best part, and your insider tip: once you have decided to create a custom die, you can change any and all features and it won't affect the cost. If you are going to slightly change the pocket shape, you might as well do the fun squiggle cut out in the front. It won't cost any more. If you add a lot of paper and weight, or if the change will requires additional gluing or hand assembly, then sure the price will go up. But if it is in the die only, take advantage of the unique die and go for it!

  • What is a die cut fixture or mold, and how is it used in manufacturing?

    A die is a little like a cookie cutter. It is a shape that is used to cut out the packaging. Once printed and cut out, the packaging is then a glued/assembled and ready for disc insertion. If you change a feature of the packaging shape, you need to change the die. Here is what a die looks like:

    die cut fixture mold for custom cd dvd packaging
    die cut fixture for packaging reverse side
    diecut fixture knife scoring blade printing manufacturing production process custom
    die cut mold for cd dvd packaging
  • Lettering Knock Outs on Packaging

    Do custom dies include lettering knock outs? Oh sure! Have fun with it—your company logo, your band, or the big guy Himself:

    custom die cut cd packaging lettering knockout
    die cut cd packaging with lettering knockouts
    lettering die cut cd packagingcustom die cut lettering on cd jacket slipcase
    Or you cut out the area around an area to highlight a logo or lettering, like this:
    die cut window custom cd packaging
    custom die cd packaging with diecut window
  • Die Cut Windows and Holes

    Looking to showcase a cartoon character or a logo or part of your booklet art? Windows can come in all sizes and shapes, take a look:

    die cut circle and notch in custom cd slipcase packagingdie cut hole in dvd slipcase packaging
    custom die dvd pacakging with diecut slipcase
    custom die cut dvd pacakging with notebook slipcase belly band OBI stripcustom die slipcase cd dvd packging knockout shapecustom dvd packaging die cut knockoutscustom die dvd slipcase showing knockout holesdie cut window cd packaging slipcasecustom cd slipcase die cut windowdie cut hole in cd slipcase spot glossdie cut circle in cd slipcase packaging

    Cellophane in a window is an option too:

    custom die cut dvd mailer 3d pop up disccellophane window die cut dvd mailer packgingcustom dvd mailer with 3d pop up disc die cut
  • Die Cut Windows to allow for Personalization

    You can even use a die cut to allow something else to personalize the product - like a photo or a booklet or a business card. maybe even the cd itself. This allows for a very cost effective run of generic company packaging that can be customized per client. You can put in your client's booklet or photo in the front pocket. Perhaps put a business card slot on the inside along with the disc. This is a great option for photography studios, video production/video post companies, Realtors—anyone who produces small quantities of discs and printing, but who wants to do so while presenting a professional image.

    And speaking of small runs with a professional look, you might want to explore our pre-printed CD-R and pre-printed DVD-R options!

    die cut window in dvd packaging to show bookletdie cut window dvd packaging bookletcustom die dvd pacakging window spot gloss matte lamclose up of die cut window dvd pacakgingcustom dvd digipak die cut window for booklet insertcustom die dvd packaging black fiberboardcustom dvd die cut packaging disc insert fiberboardcustom die dvd packaging die cut windows in fiberboardcustom photo dvd holder packaging digipak
  • Custom Die Shape CD & DVD Packaging - Fun with Folding

    Do you want these to fold up in a certain way? Not a problem. Crosses and pluses are popular.

    custom die dvd cross shaped digipak packagingdie cut dvd packaging cross shape digipakdie cut cd pacakging cross shape digipakdie cut cross shape digipak cd packagingdie cut cross shaped cd packaging 4disc setcustom die cross shaped cd digiapk 4 disc setcross shaped digipak die cut customcustom die cd cross shape packagingcustom folding digipak die cutdie cut cd pacakging cross shape digipakcustom die cd jacket packagingcustom die cut cd jacket
  • Custom Die Cut PopUp Pak, 3D Packaging for Discs

    Oh yes, we can do this too! In fact for us it has become almost like a (gasp) part number. Even our custom pop up pak has variations, dies upon dies. Feel free to vary the heights or pockets or add or subtract features. We may need to play with the pop up bit to make sure it doesn't stick.

    custom die disc packaging popup pakdie cut cd packaging popupcustom die pop up disc packagingcustom die dvd pop up pack die cut dvd pop up 3d packagingdie cut dvd pop up packaging mailercd popup mailer packaging address uncoated areacd pop up die cut pacakging frontdie cut cd pop up mailer with cardcustom die disc pop up mailer with carddie cut cd invitation packagingcd packaging with Velcro Tabcustom die disc pop up packagingdie cut cd packaging pop up with bookletdie cut cd pop up packagingcustom die packaging 3D disc holderdie cut packaging 3D disc holder3d disc packaging die cutvecro tab cd dvd packaging

    Roll over clockwise, from the top left, to see the popup jacket in action.

    pop up pak die cut disc packaging demo
    cd flip pack anim6, 4pp, pop up
    cd flip pack anim5, 4pp, pop up
    cd flip pack anim4, 4pp, pop up
    cd flip pack anim1, 4pp, pop up
    cd flip pack anim2, 4pp, pop up
  • Custom Die Shaped Pockets on CD or DVD Packaging

    It is very easy to vary the shape of the pocket. If you don't see what you want - ask. If we don't have it, we can make it. You do NOT want to ask how many thumbhole variations we have.

    custom cd packaging curved pockets
    curved pocket cd packaging custom die
    custom cd music packaging curved pockets 2disc
    custom die curved pocket cd packaging
    die cut pockets dvd packaging to hold literature
    tall cd jacket with curved pockets 3disc
    dvd jacket with two disc pockets custom shape
    tall dvd jacket two disc with custom literature staggered height
    dvd jacket with pinch pocket wide
    custom diagonal pocket cd digipak packaging
    tall dvd jacket with custom pocket for booklet
    custom diecut cd jacket pocket
    business card pocket in dvd packaging
    curved center pocket cd jacket
    tall dvd jacket fiberboard slit pocket for insert
    custom pocket guitar die cut cd packaging
    custom cd jacket trifold curved pocket center

    Our packages are two-ply thick at the panels, but are only one-ply thick at the spines. This allows the spines to move (and so that the front cover of the package won’t always be open when set flat on a table). RIP or PIPS will print on the reverse side of the stock at the spine and/or inside the pockets, so when constructed the spines will be beautiful! Say goodbye to white inside spines! RIP or PIPS will be setup by your graphics specialist if it is included in your project specification.

  • Playing with Cut Outs - Fun Squiggles

    Can the shapes be odd? Oh yes. Have fun.

    JimCapobiancoLeo26 diecut digipak, 6pp, booklet, companion, debossing, diecut window, double wall slipcase, fiberboard, halfcircle HCTH, Matte Lamination, perfect bound, rip PIPS, slipcase, spot UV, tall, digipak
    JimCapobiancoLeo26 diecut digipak, 6pp, booklet, companion, debossing, diecut window, double wall slipcase, fiberboard, halfcircle HCTH, Matte Lamination, perfect bound, rip PIPS, slipcase, spot UV, tall, digipak
    JimCapobiancoLeo27 diecut digipak, 6pp, booklet, companion, debossing, diecut window, double wall slipcase, fiberboard, halfcircle HCTH, Matte Lamination, perfect bound, rip PIPS, slipcase, spot UV, tall, digipak
    JimCapobiancoLeo28 diecut double wall slipcase, 6pp, booklet, companion, debossing, diecut window, double wall slipcase, fiberboard, halfcircle HCTH, Matte Lamination, perfect bound, rip PIPS, slipcase, spot UV, tall, digipak
    JimCapobiancoLeo29 diecut double wall slipcase, 6pp, booklet, companion, debossing, diecut window, double wall slipcase, fiberboard, halfcircle HCTH, Matte Lamination, perfect bound, rip PIPS, slipcase, spot UV, tall, digipak
    Garvey1 dirtyGuvnahs 4pp fiberboard hub jacket 8pp poster custom diecut
    blackfire3 8pp hub jacket diecut, 8pp, jacket, recycled
    blackfire 8pp hub jacket reverse inside printing diecut 2, 8pp, jacket, recycled
    blackfire 8pp hub jacket reverse inside printing diecut 1, 8pp, jacket, recycled
  • Use die cut packaging to hold items, like USBs

    USBs are very easy for us. Let us know the details of what you need in the USB and we can manufacture it. Foam helps too. It is also die cut to hold and cushion the retail item.

    usb packaging small printed box with foam insertusb box with foam insert printed 4Cusb and disc packaging digipak with foam traycustom disc packaging with usb die cut

    Need to hold your yo-yo? you didn't see that one coming. We can do that too.

    custom disc packaging to hold toy or object
    custom disc packaging with retail item


    custom dvd with pencil or pen packaging art kit

    Pencils or pens? Not a problem. Oftentimes we can also provide the retail item. Let us know the details.

  • Die Cut Discs - How about Clear Substrate Discs?

    Can we do die cut dies? Well, yes and no is the answer. Custom shaped discs have almost gone by the wayside. We can make a disc from the sized mold that is closest to finished dimension, and cut it to a special shape. However, as technology has progressed, disc drive speeds have increased and that means that your disc has to be incredibly balanced to play at fast speeds. If you really, really want one, we can probably do it. Be warned, it will be time intensive and expensive. What we recommend instead is a clear substrate cds. Let your art be the die cut. The clear substrate is a lot of fun to play with and best of all - no playability problems. Second best of all, they are not expensive to make. They do require a run of 1000 units and a little extra time.

    clear substrate cd
    clear cd disc showing front view 4C printing
    clear cd back side view showing data substrate
    Clear Substrate DVD children
    clear substrate cd disc for childrens titles
    clear cd disc 4C printing
    clear cd with packaging
    clear cd disc 1C white printing
    clear substrate cd for realtors
  • What Type of Packaging do you want a die cut on?

  • Packaging Only? Minimum Quantity?

    We generally do complete projects including the disc manufacturing. If you absolutely want packaging only, we might be able to do it for you. However it will not be as cost effective as if you did it all under one roof, and we can't complete the project for you and shrinkwrap the final product. We do not accept other plant's discs.

    A minimum qty run is about 500 - 1000 units, and you'll find the cost is pretty close between those two numbers. We can do 300 as well, but it's not particularly cost effective. If you are looking to sell these items and need a low cost per unit, you want to manufacture a many as possible. If it is a limited or test market, a small amount might make sense. With offset printing and pressed discs, there are certain set up costs involved (these are large presses) so manufacturing is better suited to large commercial runs.