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How to choose the right corner radius for your security labels
A practical buying guide — pick the right cut the first time, avoid reprints, and get labels that look sharp and last longer on any surface.
Complete corner radius chart — 1/64" (0.397mm) through 1" (25.4mm) — reference this before placing any tamper evident, void, holographic, or destructible label order with Intertronix. How to use it: find your corner shape visually, then use the fractional or decimal inch value when submitting your artwork or order.
Step-by-step: how to pick your corner radius
Answer these four questions in order and you'll land on the right size every time.
What surface are you labeling?
Flat, rigid surfaces (electronics, boxes, hard cases) — any corner radius works. Curved, flexible, or frequently handled surfaces (bottles, tubes, pouches, equipment) — use 1/8" or larger. Rounded corners distribute stress away from the edge, dramatically reducing peel-back on non-flat surfaces.
What label material are you ordering?
Metallic void / TamperVoid® labels — standard is 1/8". Holographic labels — typically 3/16". Destructible labels — use 1/16" or smaller; large corner radii on destructible material can cause the corner to break off prematurely. Non-residue labels — 1/8" is ideal. Color security labels — any size works; match your brand guidelines.
What aesthetic fits your brand?
Technical / industrial / pharmaceutical — sharp to minimal rounding (1/64" to 1/16") conveys precision. Consumer products / retail / food & beverage — moderate rounding (1/8" to 1/4") looks clean and modern. Cosmetics / premium packaging / lifestyle — generous rounding (3/8" to 1/2") reads as premium and contemporary.
Confirm your spec before ordering
Use the chart above to lock in your size in all three formats. When submitting your order or artwork file, always provide the decimal inch value (e.g., 0.125") — this is what design software and our production team use. The fractional and mm values are for reference and communication.
Recommended corner radius by label type
A quick reference for Intertronix's most popular security label categories. Highlighted rows are the most frequently ordered size for that label type.
| Label type | Recommended radius | Why | Also works |
|---|---|---|---|
| Metallic Void / TamperVoid® | 1/8" (3.175mm) Most popular | Balances tamper reliability and clean appearance | 1/16", 3/16" |
| Holographic Security Labels | 3/16" (4.763mm) | Prevents corner delamination on holographic film | 1/8", 1/4" |
| Destructible Labels | 1/16" (1.588mm) Recommended | Minimizes corner breakage on fragile substrate | 1/32", 1/8" |
| Non-Residue Security Labels | 1/8" (3.175mm) | Clean removal without corner tearing | 3/16" |
| TamperColor® Security Labels | 1/8" (3.175mm) | Standard for color label runs | 1/4", 3/8" |
| Industrial / High-Resistance Labels | 1/16" (1.588mm) | Sharp edges hold better on rough surfaces | 1/8" |
| Jewelry Security Tags | 3/16" (4.763mm) | Soft corner looks premium on jewelry tags | 1/4" |
| Asset Identification Labels | 1/8" (3.175mm) | Industry standard for asset tracking | 1/16", 3/16" |
| Food Tamper Seals | 1/4" (6.35mm) | Rounded corners prevent snagging on packaging | 3/8", 1/2" |
| Hospitality & Area Seals | 1/4" (6.35mm) | Premium look for doors, bottles, and packaging | 3/8" |
Corner radius by industry & application
Match your corner radius to how your labels will actually be used in the field.
3 corner radius mistakes that cause reprints
1. Specifying radius instead of diameter (or vice versa)
The corner radius chart — and all Intertronix order forms — use radius, not diameter. A 1/4" radius is a circle with a 1/2" diameter. If your designer draws a 1/4" diameter corner in their software and you order a 1/4" radius, your corners will be twice as rounded as expected. Always confirm which measurement your design file uses before submitting.
2. Using a large radius on destructible material
Destructible label material is intentionally fragile. A corner radius above 3/16" leaves very little material at the corner tip — it will break off before the label is even applied, or trigger false tamper evidence. Stick to 1/16" or 1/8" for all destructible label orders.
3. Choosing a radius that doesn't match the artwork
If your label artwork has a printed border or design element that follows the edge of the label, the artwork corner must match the die-cut corner exactly. Mismatched artwork and die radii create a white (or misaligned) gap at the corners. Always send your corner radius spec to your designer before artwork is finalized, not after.
Frequently asked questions
What corner radius is best for tamper evident labels?
For most tamper evident and void security labels, 1/8" (3.175mm) is the industry standard. It balances durability, adhesion, and a clean professional appearance. Destructible labels perform best at 1/16" or smaller to maintain structural integrity at the corners.
Does corner radius affect how a security label tampers?
Yes. Sharp corners concentrate peel stress and can cause premature edge lifting or early tamper activation on sensitive or curved surfaces. A slightly rounded corner — 1/16" to 1/8" — distributes stress more evenly and improves the consistency of tamper evidence across your entire label run.
Can I order a sample to test the corner radius before committing to a full run?
Yes — and we strongly recommend it. Intertronix offers free sample packs so you can test the label material, adhesion, tamper behavior, and corner radius on your actual surface before placing a production order. Request your free sample pack here.
Can I order a custom corner radius not shown in the chart?
Intertronix offers all standard corner radius sizes from 1/64" to 1". For non-standard sizes, contact the sales team at sales@intertronix.com to discuss custom tooling options for your order.
Does my corner radius choice affect the price?
Standard corner radius sizes use existing tooling and do not add cost. Non-standard or custom corner radii may require custom die tooling, which can add a one-time setup fee. All standard sizes shown in the Intertronix corner radius chart are available at no additional charge.
What is the difference between a die-cut label and a square-cut label when it comes to corner radius?
A square-cut label has 0" corner radius — perfectly sharp 90° corners. A die-cut label uses a metal cutting die and can be produced with any corner radius from 1/64" to 1", or even custom shapes. All tamper evident and security labels from Intertronix are die-cut, making any corner radius in this guide available for your order.
Ready to order? Get a free sample first.
Test the corner radius, material, and tamper behavior on your actual surface — before committing to a full run. Free samples shipped worldwide.
