Laser cutting is an incredibly precise and efficient fabrication method, but mistakes in the design or setup process can lead to wasted materials, increased costs, and unsatisfactory results. Whether you’re new to laser cutting or looking to refine your approach, understanding common mistakes can help you avoid costly errors. Here are the most frequent laser cutting mistakes and how to prevent them.
1. Using the Wrong File Format
One of the most common issues in laser cutting is submitting the wrong file type. Most laser cutting machines require vector-based files such as DXF, SVG, AI, or EPS. Using raster formats like JPEG or PNG will not produce the desired cut.
How to Avoid It:
- Always check with your laser cutting provider to confirm the required file format.
- Use vector design software like Adobe Illustrator, CorelDRAW, or Inkscape to create proper files.
2. Not Accounting for Kerf Width
Kerf refers to the amount of material removed by the laser during the cutting process. If kerf is not considered, parts that need to fit together may end up too loose or too tight.
How to Avoid It:
- Identify the kerf width for your specific material and laser settings.
- Adjust your design dimensions to account for the kerf to ensure proper fitment.
3. Ignoring Material Constraints
Different materials react differently to laser cutting. Some may warp under high heat, while others might burn or release toxic fumes.
How to Avoid It:
- Research the properties of your chosen material before cutting.
- Avoid cutting materials like PVC, which can produce harmful gases.
- Perform test cuts on a small sample before proceeding with a full-scale project.
4. Overlooking Proper Spacing Between Cuts
Placing cuts too close together can cause excessive heat buildup, leading to material warping, burning, or incomplete cuts.
How to Avoid It:
- Leave sufficient spacing between cuts, especially for thin or heat-sensitive materials.
- Optimize your design layout to balance material usage with cut quality.
5. Using Inappropriate Laser Settings
Incorrect power, speed, or focus settings can lead to poor cut quality, excessive burns, or even machine damage.
How to Avoid It:
- Refer to your laser machine’s guidelines or your cutting provider’s recommendations for the correct settings.
- Run test cuts to fine-tune speed, power, and focus before executing the final cut.
6. Forgetting to Convert Text to Outlines
If you include text in your laser-cut design without converting it to outlines, it may not display correctly on different computers or laser systems.
How to Avoid It:
- In Adobe Illustrator, select the text, then go to Type > Create Outlines before saving the file.
- Always double-check the final file to ensure the text appears as intended.
7. Not Testing Before Production
Skipping the testing phase can lead to unexpected problems, wasting materials and time.
How to Avoid It:
- Conduct a small test cut before running a full production job.
- Print a 1:1 scale design on paper to check dimensions and layout accuracy.
Laser cutting mistakes can be costly, but by planning ahead and following these best practices, you can achieve precise, high-quality results every time. Taking the time to test, adjust, and optimize your designs will help you get the most out of your laser cutting projects.
At Quote Cut Ship, we provide expert on-demand laser cutting services with precision and efficiency. Upload your design today and let’s bring your ideas to life with flawless cuts!