Laser Cutting Guidelines

Whether you're designing a one-off prototype or preparing parts for production, following good laser cutting design practices can help reduce manufacturing issues, improve part quality, and minimise costs.

This guide explains the key considerations when preparing files for laser cutting and will help ensure your parts are ready for manufacture from the moment you upload them to Performax Engineering.

Supported File Formats

For the most accurate quoting and manufacturing results, we recommend uploading:

• DXF (preferred)
• DWG
• STEP
• STP

Vector-based files provide the best results because they contain precise geometry that can be processed directly by our manufacturing software. If your design exists in another format, contact our team for assistance.

Design at Full Scale

Always create your design at a 1:1 scale. Most CAD programs allow you to set drawing units (mm/inch). Ensure these are correct before exporting your file.

Common issues caused by incorrect scaling include:

• Incorrect hole sizes
• Parts arriving larger or smaller than intended
• Quoting inaccuracies
• Assembly fitment problems

Before uploading your file, confirm that all dimensions match your design requirements.

Minimum Hole Sizes

Very small holes can be difficult to manufacture accurately, particularly in thicker materials. Where possible, larger holes produce better results and improve production efficiency. As a general guideline:

Minimum hole diameter = at least 50% of material thickness

Material Thickness	Recommended Minimum Hole
2mm	1mm
3mm	1.5mm
6mm	3mm
10mm	5mm

 

Avoid Extremely Narrow Features

Thin tabs, small bridges, and delicate sections may distort during cutting or handling. A design that looks acceptable on screen may become fragile once cut from metal. To improve part strength:

• Maintain adequate material around holes
• Avoid long, thin unsupported sections
• Increase feature widths where practical
• Consider the final application and loading requirements

Internal Corners and Sharp Geometry

Laser cutting can produce highly accurate internal corners, but sharp transitions can sometimes create stress concentration points. The below changes can improve both manufacturability and part durability

• Add small internal radii
• Use smooth transitions between features
• Avoid unnecessary sharp notches

Hole Placement Guidelines

Placing holes too close to an edge can weaken the material and increase the risk of distortion. As a general rule:

Keep holes at least one material thickness away from external edges.

Text, Logos and Cut-Outs

Laser cutting can create custom text, branding, and decorative features directly into your part. When designing cut-out text:

• Use bold fonts where possible
• Avoid extremely fine lettering
• Ensure enclosed characters remain connected
• Add bridges to letters such as A, B, D, O, P and R

Stencil-style fonts often provide the best results for cut-through text.

Remove Duplicate Lines and Open Profiles

Before exporting your file, check for:

• Duplicate geometry
• Overlapping lines
• Open contours
• Stray points
• Hidden objects

These issues can cause quoting errors or manufacturing delays. Most CAD programs include validation tools that can identify problematic geometry before export.

Weight Reduction vs Cut Time

Adding holes, slots, or honeycomb-style patterns can reduce part weight while maintaining strength. However, these features increase the total cut length, resulting in longer laser cutting times and higher manufacturing costs. When designing lightweight parts, consider the trade-off between weight savings and production cost.

Sheet Warping and Heat Distortion

Laser cutting introduces heat into the material, which can sometimes cause sheets or parts to warp, particularly in thinner materials or designs with large cut-out areas. While every effort is made to minimise distortion, some degree of warping can occur as a natural result of the cutting process. To minimise distortion:

• Avoid excessive cut-outs in a small area
• Maintain consistent material distribution where possible
• Use thicker material if flatness is critical
• Consider adding bends or structural features to improve rigidity

Pre-Upload Checklist

Before requesting a quote, confirm that:

✓ File is exported in a supported format

✓ Design is drawn at 1:1 scale

✓ All geometry is closed and complete

✓ Duplicate lines have been removed

✓ Hole sizes are suitable for the selected material

✓ Small features have been reviewed for strength

✓ Material thickness has been confirmed

✓ Part dimensions have been checked

✓ Sheet warping or heat distortion has been considered

Get an Instant Laser Cutting Quote

Once your file is ready, simply upload it to the Performax Engineering online quoting platform. Our system provides fast pricing and allows you to review material options before placing your order. Whether you need a single prototype or a production run, our team can help turn your design into precision-manufactured parts.