How to prepare a file for laser cutting

What file does laser cutting need — DXF or DWG?

Cutting software needs vector contours. DXF is a common exchange format; agree its version and compatibility of DWG, AI, CDR, SVG or vector PDF in advance. After export, check scale, layers and closed contours. JPG, PNG and BMP are raster references that need vectorization before cutting; confirm that work’s scope and cost separately.

• DXF — agree the version with the provider
• DWG, AI, CDR, SVG, vector PDF — check compatibility
• JPG, PNG, BMP — not cuttable directly, needs vectorization

Why must the drawing be 1:1 scale with closed contours?

The drawing must be made at real size — 1:1 scale, in millimeters, not inches. A file that has been scaled up or down produces a part cut at the wrong size. The second condition is closed contours: each line must start and end at the same point, with no gap. With an open contour the software cannot tell inside from outside, and the cut comes out incomplete. Also delete duplicate and overlapping lines: a doubled line means the laser passes the same path twice, which burns the edge and adds cutting time. Before sending, run your program's 'join/weld' and 'overkill' functions, which find both faults automatically.

What is the minimum hole diameter for laser cutting?

Assessing hole diameter involves sheet thickness, metal grade, nearby contours, assist gas and machine settings. Heat accumulation in small holes can affect shape and edge quality. Send the required dimensions and tolerances; the team confirms the manufacturable minimum from the drawing. If the requirement does not suit laser cutting, the material, geometry or subsequent processing may need to change.

How much clearance do parts need, and what is kerf?

Kerf is the width of material removed by the cut and depends on the material and machine settings. Specify the required finished dimensions and tolerances in the drawing. Agree on kerf compensation before adjusting geometry so it is not applied twice in the drawing and machine program. Press-fit parts, small holes and tightly nested outlines also need review of heat effects and spacing.

How do I separate cut lines from engrave lines in one file?

If one part needs cutting and engraving, separate its contour and image by colour or layer. Agree the colour convention with the provider and describe it in the file. Convert text to outlines with “Convert to Curves” or “Create Outlines” so a missing font on another computer does not change the lettering. Character height, stroke width and readability depend on material and engraving method; assess small text with a sample.

What if the part needs bending?

For bending, specify the flat pattern, bend lines, angle, radius and metal grade. A flat pattern is not simply the sum of the finished sides: bend allowance depends on material and tooling. Separate cutting and bending layers. Confirm bending availability, provider and the final flat pattern before ordering; plan production from the approved version.