How to Fix Die Cutting Tears with a Paper Shim

If you’ve ever run a detailed die through your machine only to find the paper torn or the cut incomplete, you know how frustrating it can be. Die cutting is both an art and a science, and getting the pressure just right is key to clean results. A paper shim is one of the simplest and most effective tools in any crafter’s arsenal for solving these issues. By adding a thin piece of paper to your die-cutting sandwich, you can fine-tune the pressure without investing in expensive accessories.

In this guide, we’ll explore everything you need to know about using a paper shim to fix common die cutting problems like tearing and incomplete cuts. Whether you work with delicate vellum or thick chipboard, mastering the shim technique will save you time, materials, and frustration. We’ll cover when to reach for a shim, how to make one, where to place it, and how to troubleshoot stubborn imperfections.

Before diving into the specifics, it helps to understand how a die cutting sandwich works and why pressure matters so much. The sandwich is the stack of plates, shims, dies, and material that passes through the rollers of your machine. Even small changes in thickness can make a big difference, and that’s exactly where a paper shim shines.

Quick Answer

A paper shim is a thin sheet inserted into the die-cutting sandwich to boost pressure slightly. Use it when cuts are incomplete or materials tear. Add one or two layers of copy paper on top of the sandwich and test, adding more if needed.

Understanding the Die Cutting Sandwich

Every manual die cutting machine uses a sandwich structure that feeds through the rollers. The exact configuration depends on your machine model, but the basic principle is the same: a base platform, a cutting pad, the die, your material, and a top cutting pad. The pressure applied by the rollers forces the die blades through the material and into the top pad, creating the cut.

The thickness of this sandwich is critical. If it’s too thin, the rollers won’t apply enough force to cut through the material. If it’s too thick, the machine may jam or apply excessive pressure, leading to tearing or damaged dies. Manufacturers provide recommended sandwich recipes for standard materials, but when you stray from the norm—using thicker cardstock, multiple layers, or delicate specialty papers—you often need to adjust pressure manually. That’s where a paper shim becomes invaluable.

How Pressure Affects Your Die Cuts

Pressure is the invisible force that makes die cutting possible. Too little pressure leaves the die partially cut, with fibers still attached. Too much pressure can crush the paper, deepen the die blades into the mat prematurely, or tear fragile materials. Even the best machines can’t automatically adjust for every type of paper or cardstock, so it’s up to the crafter to dial in the right amount of compression.

Several factors influence required pressure: material thickness and density, die sharpness and intricacy, the condition of your cutting pads, and even the ambient humidity. Warped or worn plates are a common culprit behind inconsistent cuts. By using a paper shim, you can compensate for these variables without replacing your entire set of accessories.

When to Use a Paper Shim

You don’t need a shim for every project. With new plates and standard cardstock, the factory-recommended sandwich usually works. However, there are clear signs that a paper shim could solve your problem:

• The die cuts through only part of the material, leaving uncut spots or a light impression.
• You’re working with thin, slippery, or textured paper that doesn’t feed evenly.
• Your cutting pads are older and slightly warped, causing uneven pressure across the plate.
• You’ve switched to a different brand of cardstock that is slightly thinner than your usual supply.
• The die has intricate details that aren’t fully cutting, even after multiple passes.

If you notice partial cuts, particularly in the center of the die, adding a shim often fixes the issue instantly. For tearing, though, the cause is usually too much pressure. In that case, a shim can still help—by placing it in a different location (such as under the material or between the die and the material) to act as a buffer and reduce friction. We’ll cover that in the troubleshooting section.

How to Create and Position a Paper Shim

Making a paper shim is incredibly simple and costs nothing. You likely already have suitable materials in your craft room. The key is to choose a paper that is thin, consistent, and doesn’t compress too much under pressure. Copy paper (20 lb or 75 gsm) is the most common choice because it’s widely available and provides a predictable increase in thickness—about 0.004 inches (0.1 mm) per sheet.

To create a shim:

1. Cut a piece of copy paper slightly smaller than your cutting plates. You don’t want it to stick out or interfere with the roller edges.
2. Place the shim on top of your completed sandwich, right where the rollers will apply pressure. In most machines, this means placing it on top of the uppermost cutting pad.
3. Run the sandwich through the machine as usual.
4. Check the result. If the cut is still incomplete, add another layer of shim paper and test again. Repeat until you get a clean cut.

Be cautious: adding too many shims can strain your machine or damage the dies. Always start thin and build up gradually.

Materials for Paper Shims

While office paper is the go-to, you can experiment with different materials depending on your needs. Vellum or waxed paper can be used as a temporary shim to reduce friction and help dies release from sticky materials. Cardstock shims are useful when you need a more substantial lift, but they can be too aggressive for delicate dies. Aluminum foil or plastic shim stock is an option for those who want a reusable, precise shim, but they may void warranties on some machines, so check your manual first. For most troubleshooting, simple printer paper works perfectly.

Where to Place the Shim in Your Sandwich

The standard placement is on top of the entire sandwich, directly under the upper roller. This increases the overall thickness and forces the rollers to compress more. However, there are times when a different location yields better results:

• Under the material: Placing a shim between the material and the die can lift the material slightly, which sometimes helps clean up an incomplete cut in the center of intricate dies. This technique is often used with thin dies that don’t cut deeply.
• On top of the die: If the die itself is slightly warped, a small shim placed directly on the affected area can even out the pressure.
• Between the cutting pad and the platform: If your cutting plates are very worn, adding a shim underneath the bottom pad can raise the whole stack and compensate for the plate’s thinness.

Experimentation is key because every machine model has a slightly different sweet spot. Keep notes of what works for your most-used dies and materials.

Troubleshooting Common Issues

Incomplete Cuts

Incomplete cuts are the most common reason to reach for a paper shim. If you see that the die has only lightly indented the paper or that some areas remain connected, your sandwich is likely too thin. Start by adding one shim on top of the cutting pad. If that doesn’t work, try two. Important: always test with scrap paper to avoid ruining your project material. Keep adding shims until the die cuts cleanly through, but stop if you feel excessive resistance when turning the handle. If you need more than three or four shims, there may be another issue, such as a dull die or extremely thick material that requires a different approach.

Material Tearing

Tearing can be trickier. While a paper shim is often associated with adding pressure, it can also mitigate tearing when used correctly. If your paper tears during cutting, the die may be applying too much pressure, or the material may be bunching up. Try placing a sheet of wax paper or parchment between the material and the die. This acts as a release layer, reducing friction and allowing the die to slice rather than tear. Alternatively, if the tearing is happening because the die is cutting into the mat too deeply, you can create a “reverse shim” by adding a thin piece of cardstock under the material to lift it slightly, which can shallow the cut depth. Another trick: place the paper shim inside the sandwich, between the cutting pad and the material, to provide a buffer that absorbs some of the sharpness without adding overall thickness.

Die Not Cutting Through Certain Areas

Sometimes a die cuts perfectly except for one stubborn corner. This often happens with intricate dies that have narrow channels or deep crevices. A paper shim can be used as a “spot shim” in these cases. Cut a very small piece of paper—just big enough to cover the problem area—and tape it lightly to the back of the die or to the cutting pad directly above that section. The extra thickness will concentrate the pressure and push the blade through. Run the sandwich through once, and the spot should cut cleanly. This technique saves you from having to shim the entire plate and risking damage elsewhere.

Advanced Shim Techniques for Different Materials

Not all materials behave the same way under a die cutting machine. Here’s how to adapt your shimming for various craft papers and cardstocks:

• Vellum and thin parchment: These often tear easily. Use a paper shim under the material to cushion it, and place a piece of wax paper on top to prevent the die from grabbing.
• Glitter cardstock: The coarse surface can cause incomplete cuts. A shim on top of the sandwich adds the extra pressure needed to push through the textured layer.
• Felt and fabric: Thicker materials may require multiple shims. Place them on top of the cutting pad, but be aware that too many can compress the fabric and distort the shape.
• Magnetic sheets: For cutting magnetic material, you may need a very firm sandwich. A paper shim can help, but many crafters prefer a metal shim for consistency. However, a folded sheet of heavy copy paper often suffices for one-off projects.

Using Multiple Shims for Fine-Tuning

When a single paper shim isn’t enough, you can stack them methodically. Always add shims one at a time and test. Instead of folding the paper, which creates uneven thickness, cut multiple identical sheets and store them together. Label your shims with the material and die combination for quick reference. For example, “Two shims for double-sided tape glitter card with intricate die.” This saves time on future projects.

Maintaining Your Die Cutting Machine and Plates

While a paper shim extends the life of your cutting plates by compensating for wear, it’s not a permanent fix. Regularly rotate and flip your cutting pads to distribute usage evenly. Clean your plates with a lint roller or mild soap to remove paper dust and adhesive residue, which can alter sandwich thickness. If you find yourself relying on shims constantly, it may be time to replace your cutting pads. New pads restore the original sandwich thickness and reduce the need for shims.

Conclusion

Mastering the paper shim technique is an essential skill for anyone who loves die cutting. This simple tool solves a wide range of problems, from incomplete cuts to material tears, without requiring expensive upgrades or complex adjustments. By understanding how pressure works and learning to fine-tune it with a paper shim, you can achieve professional-quality results on almost any material. Remember to start thin, test on scraps, and keep clear records of your successful shim setups. With a little practice, you’ll be able to rescue any project and extend the life of your dies and plates. So next time your die doesn’t cut as expected, don’t get frustrated—just reach for a piece of paper and let the shim do the work.

FAQ

Can a paper shim damage my die cutting machine?

When used correctly, a paper shim is safe. However, stacking too many shims can force the rollers and cause strain. Always start with one layer and stop adding shims if you feel strong resistance. Never use shims to the point where the machine jams or the handle is difficult to turn.

How many paper shims can I use at once?

Most machines can handle two or three layers of copy paper without issue. Some crafters use up to five, but this risks bending the plates or wearing out the rollers prematurely. If you consistently need more than three shims, consider inspecting your dies, plates, and machine for other problems.

What type of paper is best for a paper shim?

Standard printer paper (20 lb) is the most reliable because of its uniform thickness. Waxed paper, vellum, or parchment can also work for special situations like preventing sticking. Avoid textured or fibrous papers that compress unevenly under pressure.

Can I reuse a paper shim?

Yes, as long as it remains flat and dry. If a shim becomes wrinkled, creased, or damp, it will not provide consistent pressure and should be replaced. Store flat shims in a folder or envelope for future use.

How do I know if I need a paper shim or new cutting pads?

If a single shim solves your cutting issues, your sandwich thickness is only slightly off. If you need multiple shims and your plates are visibly warped, have deep grooves, or are thinner than 1/8 inch, it’s time to replace them. New pads often eliminate the need for shims altogether.

Is a paper shim the same as a metal shim?

No. A metal shim is a precision-cut piece of material, often brass or steel, used for industrial applications. In crafting, metal shims can be too aggressive and may void machine warranties. A paper shim is gentler and adjustable, making it safer for home die cutting machines.