Cutting dies are expenive to have made professionally for a custom application, and oftentimes it just seems easier to cut with an exacto knife than get a die made, especially if you will be making an unknown quantity of items. Depending on the complexity of your design and how precise your dimensions must be, making your own die can save you quite a bit of time and effort. If you must have ultaprecise dimensions, this method is not for you, but if being off by 3/32 won't cause the sky to fall, making your own cutting die is a straightforward process.
This die is designed for cutting paper. If you want something that you can put in a press and stamp thin sheetmetal with, you will need to use a different source for the blades (actual sheet or flatstock, not just the trash from last night's chili), and you will need to set these blades in wood or metal. If it's metal, tacking them in place with your arc welder is a good idea, but you will need to run a full bead (or braze) before you apply 12 tons of force. If you are building a press die, you will also need to get a small square, to make sure you have your blades at the right angle. For just cutting paper, it's nowhere near as tough, and that's what we'll be doing today.
Don't be an idiot like me and forget to sharpen all your blades before you bend them and stick them in tight corners. I have not actually sharpened this die yet, and if/when I do, I will update this with photos. Until then, you get a verbal description of what to do. It will work.
Step 1: Get Your Materials
-- You will be needing a block of floral foam large enough to fit your whole pattern on.
-- One or two metal food cans (empty them first. Yum)
-- Tin snips (don't just try big scissors
-- Gorilla glue
-- Needlenose pliers
-- Leather gloves (optional, but there will be edges ranging from kinda sharp to razor sharp)
-- Dremel tool or handheld drill (no drill press), or even a bench grinder if you are so lucky
-- Clamps or a vice (to hold things while you sharpen)
-- Grinding/sharpening attachment for your electric spinny thing of choice
-- A flat object big enough to fit over your entire pattern
-- Ruler or calibrated eyeball
-- Time and the patience to use it