How to Prepare a File for Laser Cutting: A Guide for Designers and Engineers

The importance of properly preparing a file for laser cutting cannot be overstated. A quality file saves valuable time, prevents production errors, and ensures that the final result matches the design precisely. When problems in the file are discovered only at the production stage, they cause delays and additional costs.

By understanding the technical requirements and adhering to the basic rules for preparing a file for laser cutting, you pave the way for a smooth process with a professional laser cutting supplier.

Recommended File Formats for Laser Cutting

Laser cutting machines work with vector files, meaning files based on mathematical data of lines and curves rather than pixels. The standard formats in the engineering and design industry are DXF and DWG, but AI files created with Illustrator software and vector PDF files can also be used. Image files such as JPG or PNG are not suitable for laser cutting since they are pixel-based and cannot be cut precisely.

To choose a suitable format, consider the software you are working with and the supplier’s requirements. Most laser cutting suppliers prefer to receive DXF files since they are universal and can be opened in any CAD software. If you are working with graphic design software, make sure to export in vector format and verify that all texts have been converted to outlines. Maintaining format compatibility prevents problems when the supplier opens the file and ensures dimensions are preserved without changes.

Accepted formats for laser cutting:

• DXF: The most common format, supported by all machines
• DWG: AutoCAD format, suitable for complex drawings
• AI: Created in Illustrator software, must be saved as vector
• PDF: Only in vector version, not a scanned or image-based file

Preparing a File for Laser Cutting: Basic Settings

Units of Measurement and Scale

The units of measurement in the file must be millimeters. This is the standard industry requirement aimed at preventing confusion and errors in the transition from file to production. If you are working with software set to inches or other units, convert to metric units before saving. The scale must be 1:1, meaning the dimensions in the file should represent the actual dimensions of the part. A common mistake is saving a file at a different scale, resulting in parts being manufactured smaller or larger than planned.

Colors by Operations

Line thickness in the file should be minimal, between 0.01 and 0.1 millimeters. Thicker lines may be interpreted as areas for engraving rather than cutting lines. Many suppliers use different colors to distinguish between operation types: one color for cutting, another for engraving, and a third for marking only. It is recommended to check with the supplier in advance about their color code and prepare the file accordingly. If you have not received specific instructions, use black for cutting lines and red for engraving lines.

Closed and Continuous Lines

Every line intended for cutting must be completely closed. An open line, even if the gap is very small, indicates to the supplier that you do not want to separate a layer of material in that area of the part. CAD software includes tools for checking open lines and automatically closing them. Additionally, lines in the file must be continuous, meaning not composed of multiple separate segments that appear as a single line. Fragmented lines may cause interruptions in cutting and result in an uneven outcome.

Recommended checks before sending a file for laser cutting:

• Open line check: Verify that all lines are closed
• Duplicate lines: Remove overlapping lines
• Dimension check: Verify that measurements are correct
• Text conversion: Convert all text to outlines

Common Mistakes in Preparing Files for Laser Cutting

The most common mistake is leaving duplicate lines at the same location. Such lines are frequently created when copying elements or combining drawings from different software, and they create a problem because the cutting machine will pass over the same line twice. A double pass of the laser cutting machine causes the part to be cut too deeply or the material to burn. CAD software contains dedicated commands for identifying and removing duplicate lines. It is worth running them before every export.

Attention should also be paid to spacing. Between elements within the design, a spacing of at least one millimeter should be maintained, and between separate parts on the sheet, a spacing of 3 millimeters is recommended. Spacing that is too small may cause the material to warp from heat or crack during processing.

Recommended spacing:

• Internal spacing: At least 1 mm between elements within the part
• External spacing: At least 3 mm between separate parts
• Sheet edge spacing: At least 5 mm from the material edge

Text that has not been converted to outlines is a frequent source of problems. If the font is not installed on the supplier’s computer, the text appears in a different font or does not appear at all. All text must be converted to Outline or Curves so that it appears as vector shapes. This is an essential step before any submission for production.

Tips for Smooth Workflow with a Laser Cutting Supplier

Before sending a laser cutting file to a supplier to begin processing and production, it is worth printing the file at a 1:1 scale to check the dimensions with a ruler. This is a simple check designed to verify that the scale has been maintained throughout all stages of work and can save you a lot of headaches. If you intend to produce multiple parts that should fit together, it is worth printing the files for all of them and checking physical compatibility before ordering production.

Clear communication with the supplier saves time and prevents misunderstandings. It is worth clearly specifying the material type and thickness, the required number of units, and the distinction between cutting lines and engraving lines. If you have special requirements regarding grain direction of the material, specific surface finish, etc., these should be specified in advance. Experienced suppliers help prepare files for laser cutting in an optimal manner.

Admati Agencies: Laser Cutting with Close Support

At Admati Agencies, we specialize in laser cutting processes at a very high level of precision, enabling us to serve demanding industries such as defense, electronics, medical, and aeronautics. Our team is experienced in working with complex files and can assist you in making the necessary adjustments before production.

We work with a variety of materials and also offer complementary sheet metal fabrication services. If you have questions about preparing a file for laser cutting or adapting it to our requirements, you are welcome to contact us and we will be happy to assist.

FAQ About Preparing Files for Laser Cutting

What format should the file be saved in?

The most recommended format for a laser cutting file is DXF. This format is supported by all cutting machines and CAD software. Vector DWG, AI, and PDF files are also suitable, provided they are saved correctly.

What is the recommended line thickness in laser cutting files?

Line thickness should be minimal, between 0.01 and 0.1 millimeters. Thicker lines may be interpreted as areas intended for engraving rather than lines intended for cutting.

How to check for duplicate lines in the file?

CAD software contains dedicated commands for identifying and removing duplicate lines. In AutoCAD, for example, there is the OVERKILL command. It is recommended to run such a check before every export of a laser cutting file.

Do texts need to be converted before sending a file for laser cutting?

Yes, all text in the file must be converted to outlines before submission, to ensure that the text appears without errors even if the font is not installed on the supplier’s computer.

How can you verify that the file scale is correct?

The simplest way is to print the laser cutting file at a 1:1 scale and measure the dimensions with a ruler. Additionally, verify that the units of measurement in the file are millimeters.