Dies are the critical tool for achieving the desired results. There are a number of die materials available, including magnesium, copper, and brass. The decision to use one over the other is determined by the complexity of the design, the length of the run, and the desired longevity of the die.

Magnesium Dies are most commonly photo-etched. They are a fast, cost-effective and versatile choice for flat foil stamping and some single-level embossing applications. They are ideal for short runs, depending on the size of the image and type of stock. If the surface area of the foil stamped image is relatively small to medium in size, magnesium will yield excellent results. Designs that require fine detail or uneven distribution of foil require more pressure to produce and therefore, cannot be readily achieved with magnesium. In addition, when working with magnesium dies, the paper stock should either be smooth or coated.

Copper Dies are produced by a photo-etching process and are most commonly used for flat stamping and single-level embossing. Copper is an extremely hard metal with good etching attributes, which makes it an excellent choice for medium to long foil stamping runs. Copper is a good heat conductor and, therefore, maintains heat very well. This is especially important when foil stamping on high-speed equipment, where the speed and action of the press are more likely to cool the die temperature. In addition, copper is recommended for medium to larger solid areas of foil, where more tonnage and pressure are necessary on press. This helps ensure that the die does not begin to crush under the pressure of the stamping press. Lastly, if you are using a textured or recycled stock for a foil stamped image, copper is most likely the metal to use.

Brass Dies are the most versatile of all the engraving metals. They also are extremely durable and generally used when the highest quality die is required. Brass is most commonly used for hand-tooled and machined embossing engravings (multi-level or sculptured), but it also is useful for long-run flat stamping jobs due to its strength. Because it is easily tooled, brass is an ideal metal choice when an image needs to be 'opened' up so that the foil stamps cleanly without the image filling in.

Brass engravings are the industry standard for combination (foil and embossing) dies as well. When an image can be foil stamped and embossed in one pass, brass is the best choice because it can be easily machined to create the needed relief to apply foil and emboss the image simultaneously. Brass is more expensive than copper and magnesium, so you must analyze the application carefully before making your choice.

Brass is the ideal choice for CNC engraved dies (an engraving process utilizing a computerized program to machine-tool dies,) which is a growing trend in die manufacturing. CNC engraved dies are extremely precise, and eliminate the chemicals used in photo-etching dies. In addition, engravers can store the die-creation files for easy re-ordering.

Proofing
Unlike printing, proofing the die usually is  very easy. Once the die has been created, ask your stamping supplier to obtain a small sample roll of the foil you intend to use, and use it to make a proof with a sample sheet of your intended paper stock. That way, you can see the results and anticipate problems before the actual run. It's also important to allow enough time in your schedule to accommodate proofing.

Also, before the die is produced, it's a good idea to look into who retains the property rights to the die. Like some freelance artwork,  the rights to the die itself sometimes remain with the stamping company. Most often, the finished die is your property once produced – although most foil stamping suppliers will keep your dies on file. This assures that the die does not become lost or damaged in storage.

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