This guide is designed to help engineers and designers prepare CAD and vector files that meet
laser cutting requirements. Following these design guidelines before order submission can help
prevent file errors, improve cutting quality, shorten lead times, and reduce overall
manufacturing costs.
2. Vector & CAD File Preparation
A production file should contain only the closed cutting geometry required to manufacture the
part. Clean all construction elements and annotations before exporting.
Scale & Units
1:1 Scale: Build files at full final cut size. Written dimensions inside drawings are ignored by
automated processing systems.
Units: Imperial (inches) is preferred. Metric (millimeters) is acceptable when used consistently
between the file and quote. Centimeters and meters are not supported.
Manufacturing Geometry Only
Remove all dimensions, title blocks, borders, guides, notes, and annotations.
Convert Text to Outlines
Convert all text to vector outlines (or explode/expand text in CAD). Editable fonts/text boxes
cannot be recognized as cutting geometry.
Closed Cutting Profiles
Every cut path must form a fully closed shape. Inspect geometry in wireframe/outline mode before
export to detect unclosed paths or tiny gaps.
Duplicate & Overlapping Lines
Delete duplicate, overlapping, or intersecting vector entities. In multi-entity geometry,
duplicated lines can be interpreted as double-cutting paths and ruin cut quality.
Dedicated Layer Usage
Place all final cut paths on a designated cut layer. Move construction geometry or annotations
to separate layers or delete them entirely prior to export.
Bridging Floating Interiors
Internal "islands" (e.g., the centers of letters like O, A, B, or donut-shaped cutouts) will
become detached during cutting. Add bridges or stencil connections to retain them. Bridge width
depends on material thickness.
3. Laser Cutting Feature Guidelines
Feature size, internal corners, spacing, and cutout density directly affect laser cutting
quality. Check these elements against the requirements of your selected material and process.
Minimum Hole & Cutout Size
As a general guideline, the minimum hole or cutout diameter should be at least 50% of the
material thickness.
Actual limits vary depending on material type, thickness, and laser cutting capability. Very
small holes and intricate features may require engineering review before production.
Minimum Internal Radius
Internal corner size is affected by the material thickness and laser cutting process. Extremely
small internal corners may not reproduce accurately.
Allow sufficient internal radius for the selected material and process, especially for small or
tightly fitting features.
Narrow Walls & Isolated Features
Extremely narrow walls, webs, and isolated features may distort or overheat during cutting.
Maintain sufficient feature thickness based on the material and cutting process. For thin
materials, avoid long, narrow sections that can easily deform due to heat accumulation.
Dense Cutout Patterns
Intricate patterns such as grilles, ventilation holes, and speaker grates increase cutting time
and heat buildup.
For thin materials, increase the line or web thickness between cutouts if burn marks,
discoloration, or deformation occurs during cutting.
Laser Kerf
Laser cutting removes a narrow amount of material along the cutting path, known as the kerf.
Kerf width varies depending on the material, thickness, laser system, and cutting parameters.
Consider kerf when designing:
- Tight-fit or mating components
- Small holes and slots
- Narrow gaps between adjacent features
For reference, typical cutting gaps may range from approximately 0.006″ to 0.012″, depending on
material and process conditions.
Heat-Affected Areas
Laser cutting generates localized heat that can affect thin or heat-sensitive materials.
Potential effects include edge discoloration, burn marks, localized deformation, and surface
oxidation.
Avoid excessive concentrations of small features in a limited area, particularly when working
with thin materials.
Part Spacing & Common-Line Cutting
Keep sufficient spacing between adjacent parts to account for laser kerf, heat accumulation, and
process tolerances.
Do not share a cutting line between adjacent parts. Common-line cutting may affect dimensional
accuracy and edge quality because kerf and heat input are not fully accounted for.
For multiple copies of the same part, upload one file containing a single part and set the
desired quantity during checkout.
Directional & Mirrored Materials
Materials with directional or decorative surfaces, such as brushed, mirrored, or textured
sheets, may require a specific top/bottom orientation.
Save mirrored variations as separate files when surface direction matters.
