Common Mistakes in Laser Cutting Designs
Even experienced designers can make costly laser cutting design mistakes when preparing files for cutting. This guide outlines the most common errors — and how to avoid them.
Common Laser Cutting Design Mistakes
Want a visual version instead? We’ve also created an infographic summarising these mistakes — or scroll down to dive into each one.
This visual summary covers the most common laser cutting design mistakes at a glance — or scroll down to explore them in detail.
Using the Wrong File Type
Stick to vector-based files like DXF or DWG. Avoid JPGs or PNGs, which cannot be used for clean cutting paths.
Most cutting software prefers .DXF or .DWG for vector accuracy. Raster formats like .JPG or .PNG lack defined paths.
Learn more about vector files from Adobe.
Forgetting Kerf Width
Always account for kerf — the laser’s cut width (typically 0.1–0.2mm). Not adjusting for this can throw off part fit.
Kerf should be considered in both internal cut-outs and tight-fitting assemblies.
Not Leaving Enough Margin or Part Spacing
Leaving too little space between parts — or between parts and the sheet edge — can lead to distortion, heat build-up, or incomplete cuts. Always allow for:
Edge Margin: Leave at least 5–10mm from the part to the sheet edge.
Inter-Part Spacing: Leave at least 3–5mm between adjacent parts. (maybe more sometimes – just ask)
These gaps help prevent burning or melting of fine features and allow the laser to follow clean entry and exit paths. Tight nesting is important — but not at the expense of cut quality.
Overly Fine Details
Very thin lines or micro-holes may not resolve well in metal. Maintain minimum line weight and spacing (e.g. 0.5mm+).
Avoid any detail smaller than 0.5mm — these often get lost in the cut or cause thermal stress.
Laser Cutting Design Mistakes: Poor Nesting or Material Efficiency
Inefficient layouts increase cost and waste. Group parts tightly and use nesting software where possible.
Inefficient nesting = higher material costs. Even a 10% waste reduction can save money.
Skipping Test Cuts
Always test on small samples before running a full sheet — especially for new materials or finishes.
This is especially important with reflective metals (like brass or stainless steel), or bespoke patina finishes.
If you want expert help turning your corrected drawings into accurately cut parts, our thin-gauge laser cutting service provides clean, precise cutting across aluminium, stainless steel, brass, copper, zinc and more.
For designs needing tighter tolerances or detailed features, our precision sheet metal cutting service ensures consistent results from prototype through to production runs.
If you’re unsure which metal best suits your design, our sheet metal materials page outlines all the metals we cut in-house, including aluminium, stainless steel, brass, copper and zinc.
For branding plates, tags or small lettering, our laser cut signs page shows how we handle intricate shapes and decorative components.
Smaller one-off parts and test cuts can often be produced at lower cost using our laser cutting with remnants option — ideal when validating a design before moving to a full sheet.
Working specifically with thin-gauge material? Our dedicated page on laser cutting 1mm aluminium explains tolerances, finish options and best practices for lightweight components.
You can also refer to our guide to metals for laser cutting for material selection tips across all common sheet metals.
Vector files like DXF or DWG are ideal for precision cutting.
Kerf refers to the width of material removed by the laser beam — usually around 0.1–0.2mm.
Yes, testing with a small section can save time and money, especially with new materials.
Check for correct file types, adjust for kerf width, use proper spacing, and run a test cut. Our guide covers all these design mistakes in detail.