Introduction
Laser cutting mistakes can lead to wasted materials, poor-quality cuts, and increased costs. Whether you’re a professional fabricator or a designer working with metal for the first time, understanding these common mistakes will help you achieve clean, accurate cuts every time
At MS Laser Services Ltd, we work with clients to optimize their designs for stainless steel, aluminium, brass, copper, and zinc cutting. Here are the most common laser cutting mistakes and how to avoid them.
1. Ignoring Material Properties
Each metal has unique characteristics that affect the laser cutting process.
✅ Tip: Adjust power settings and cutting speeds based on material type and thickness.
✅ Example: Brass and copper are reflective metals, requiring special laser adjustments.
2. Incorrect File Formats can lead to errors
Design files must be compatible with CNC laser cutting software to ensure precision.
✅ Tip: Use vector-based file formats such as DXF, DWG, or AI for best results.
✅ Avoid: Raster images (JPEG, PNG) which cannot be directly converted into cut paths.
3. Overly Complex or Too Small Designs
Extremely intricate designs or very thin cut-outs may not translate well to metal cutting.
✅ Tip: Maintain a minimum cut width to prevent parts from melting or breaking.
✅ Example: Fine details in stainless steel should have at least 0.5mm spacing to ensure durability.
4. Kerf Width: Common Laser Cutting Mistakes
Kerf refers to the width of material removed by the laser beam, which must be factored into the design.
✅ Tip: Adjust dimensions to compensate for kerf width based on material thickness.
✅ Example: If cutting 2mm aluminium, reduce inner shapes slightly to maintain exact fit.
5. Poor Nesting & Material Utilization
Efficient placement of parts on the sheet reduces waste and lowers production costs.
✅ Tip: Use automated nesting software to maximize material use.
✅ Example: Grouping similar cuts together minimizes repositioning time and optimizes efficiency.
6. Inadequate Support for Heat-Affected Areas
Heat from the laser can warp thin metals or cause unwanted burns on intricate parts.
✅ Tip: Use proper support structures or tabs for long, thin sections to prevent warping.
✅ Example: Cutting thin stainless steel panels? Add micro-tabs to prevent movement during cutting.
7.Skipping Test Cuts – Costly Laser Cutting Mistakes
A small test cut can reveal issues before processing an entire sheet of metal.
✅ Tip: Always run a prototype cut to verify settings before full production.
✅ Example: Adjusting settings for mirror-polished brass avoids unwanted burn marks on the finish.
Why Choose MS Laser Services Ltd?
At MS Laser Services, we help clients avoid costly mistakes by offering expert advice and precision laser cutting services.
🔹 Precision Laser Cutting – Tailored settings for different metals.
🔹 Design Consultation – Optimized file preparation for smooth production.
🔹 Fast Turnaround & Competitive Pricing – Get high-quality results on time and within budget.
📩 Contact us at: contact@mslaserservices.co.uk
📞 Call us at: 0151 458 9030
Final Thoughts
Avoiding these common laser cutting mistakes can save time, reduce material waste, and improve overall project success. Whether you’re working on industrial components, signage, or custom metal fabrication, precision laser cutting ensures the best results.
📢 For expert laser cutting services, contact MS Laser Services Ltd today!
MS Laser Services Ltd is part of the Metal Sheets Group