Whether you’re a first-time maker or a seasoned designer, laser cutting offers incredible precision and endless customization options. But great results depend on a properly prepared file. At Quote Cut Ship, we review hundreds of files each week—and we’ve seen some common design missteps that can lead to frustrating results. If you’re designing for laser cutting, here are five of the most common mistakes to avoid.
1. Using the Wrong File Format
Laser cutters don’t interpret JPEGs or PNGs the way your design software does. For clean, accurate cuts, you need a vector-based format such as .DXF, .AI, or .SVG. These formats define exact paths that the laser can follow, ensuring every cut is crisp and precise. Before uploading your file, double-check that you’re working in the correct format.
2. Lines Are Too Close Together
When design lines are placed too tightly or overlap, the laser can overburn or accidentally cut into areas you want to keep intact. This often weakens the structure or leaves behind unwanted marks. To avoid this, aim for at least .010 inches of spacing between critical paths or cut lines.
3. Ignoring Material Thickness
While laser cutting is a 2D process, the material you’re working with has depth—and it matters. If you’re designing parts that interlock or need to fit together tightly, failing to account for material thickness can result in pieces that don’t fit or break easily. Always check the specs of your material and factor them into your design.
4. Open or Unjoined Paths
Unjoined or open paths can confuse the laser cutter, especially during engraving or scoring operations. The result might be incomplete shapes or erratic engraving. Use your design software’s path cleanup and “join” features to ensure every line is properly closed and connected.
5. Forgetting to Convert Text to Outlines
One of the simplest mistakes to make is leaving text in its default font format. If that font isn’t available on the machine opening your file, it may get replaced—or disappear entirely. To keep your design intact, convert all text to outlines or curves before exporting your file.
Designing for laser cutting doesn’t have to be difficult, but it does require attention to detail. Avoiding these five mistakes can save you time, money, and frustration. Whether you’re creating a prototype, product, or custom piece, following best practices ensures you get a result that looks and functions exactly as intended. And if you need help along the way, the team at Quote Cut Ship is always here to support you from upload to delivery.