Common Mistakes to Avoid When Designing for Laser Cutting

Laser cutting is a precise and efficient method for cutting and engraving a variety of materials, but even the most advanced technology can’t compensate for design errors. If you’re new to laser cutting or looking to improve your designs, avoiding these common mistakes will help ensure high-quality results and reduce material waste.

1. Using the Wrong File Format

Laser cutters require vector-based design files to accurately follow the cutting path. Some of the most commonly accepted formats include:

  • DXF (Drawing Exchange Format)
  • SVG (Scalable Vector Graphics)
  • AI (Adobe Illustrator)
  • EPS (Encapsulated PostScript)

Avoid using raster-based formats like JPG, PNG, or BMP, as these do not provide precise cutting paths.

2. Ignoring Kerf Compensation

The laser removes a small amount of material as it cuts, known as the kerf width. If you don’t account for kerf, parts that need to fit together may be too loose or too tight. To avoid this:

  • Check the kerf width of the specific laser cutter and material you’re using.
  • Adjust your design dimensions accordingly.

3. Not Converting Text to Outlines

If your design includes text, it must be converted to outlines before exporting your file. This ensures that the laser cutter recognizes the text as a shape rather than a font, preventing potential errors.

  • In Adobe Illustrator, select your text, then go to Type > Create Outlines.

4. Using Open Paths Instead of Closed Shapes

For accurate cuts, all paths in your design must be fully closed. Open paths can result in incomplete or unpredictable cuts. Use your design software’s Join or Close Path function to ensure all paths are properly connected.

5. Overlapping or Duplicate Lines

Overlapping lines can cause the laser to cut the same area multiple times, leading to excessive burning and wasted material. Before exporting your file:

  • Use the Remove Duplicates function in your design software.
  • Carefully check for overlapping lines and delete unnecessary ones.

6. Incorrect Line Thickness & Color Coding

Laser cutters differentiate between cutting and engraving based on line thickness and color coding:

  • Cut lines should be thin (0.001” or hairline width) and typically in red.
  • Engraving lines should be thicker (greater than 0.1”) and in black or grayscale.
  • Scoring lines (shallow cuts) should be in blue.

Always verify the color and thickness requirements with your laser cutting service.

7. Poor Material Selection

Not all materials are suitable for laser cutting. Some common mistakes include:

  • Using PVC or vinyl, which releases toxic fumes when cut.
  • Choosing fragile materials that may burn or warp under the laser.
  • Not considering material thickness—thicker materials require more power and slower speeds.

Always check with your laser cutting provider for compatible materials.

8. Insufficient Spacing Between Cuts

Designs with cuts that are too close together can weaken the structure of the material, leading to breakage. To avoid this:

  • Maintain at least 1-2mm spacing between adjacent cut lines.
  • Ensure small details are not too fragile to withstand the cutting process.

9. Not Testing Before Production

Skipping a test cut can result in unexpected issues, wasted materials, and design flaws. Before full production:

  • Print a paper version to check dimensions and layout.
  • Run a small test cut on scrap material to verify settings and fit.

What To Remember

By avoiding these common mistakes, you can ensure a smooth laser cutting process and achieve high-quality results. Proper preparation, material selection, and careful design adjustments will save you time, money, and frustration.

At Quote Cut Ship, we provide expert on-demand laser cutting services with instant quoting and fast turnaround. Upload your design today and let’s bring your ideas to life!