Best Practices: Designing for Laser Cutting
Save time and money by following these guidelines when designing laser-cut parts.
Computer Numerical Control laser cutting is a versatile tool capable of creating intricate designs and features in various materials. The designs produced are neat, detailed, and customizable to match different spaces.
As with any process, understanding the nuances of CNC laser cutting can significantly impact the design and final result. This article presents valuable design tips for laser-cut parts, aiming to enhance your knowledge and improve the outcome of your laser cutting projects. These general design guidelines are essential for achieving high-quality, cost-efficient laser cut projects.
CNC cutting techniques can also be applied to stylish interiors, such as wall panels and decorative doors, adding both functionality and aesthetic appeal. Laser cutters should never be operated unattended to prevent fire hazards. Additionally, a fire extinguisher should always be kept near the laser cutter during operation. Choosing the right material plays a crucial role in ensuring both safety and the quality of your finished product.
When preparing your design files, it is important to use design software that supports vector graphics. Adobe Illustrator is a popular tool for creating and editing vector graphics for laser cutting. Using vector format files is essential, as they provide mathematically precise edges and ensure accurate, high-quality laser cutting results.
Overview of CNC Laser Cutting
CNC laser cutting is a subtractive manufacturing technology that utilizes a high-power laser beam to cut flat-sheet materials. Thinner materials require less laser power to achieve clean cuts, making them more efficient for certain applications.
Using specialized laser cutting design software is crucial for creating precise and efficient designs. The process begins by designing a digital program in a CAD/CAM system that directs the laser cutter. This design file creates vector files that outline the desired shapes and dimensions of the parts. It is important to ensure the shape of the design is accurately represented in the vector file for precise cutting results. For quick reference, tools provide comprehensive information on material options and their properties.
The laser cutter, guided by the CNC system, then uses a concentrated beam of light to melt, burn, or vaporize the material along the programmed path. Kerf refers to the width of material that is removed during the cutting process, which is an important consideration for precision. The laser cut path should be offset so the kerf’s inner edge aligns with the outer edge of the intended part dimensions.
The result is a clean, smooth, and accurate cut that can accommodate complex shapes and small holes, all with minimal waste. Compared to other cutting methods, such as plasma cutting, laser cutting typically produces cleaner edges that do not require post processing, whereas plasma cutting often results in rough edges requiring post processing.
CNC laser cutting is a subtractive manufacturing technology that utilizes a high-power laser beam to cut flat-sheet materials. Wood is one of the most common materials used in CNC cutting for home decor, providing a warm and natural appearance. However, materials such as PVC should be avoided due to toxic fumes emitted during cutting. An appropriate material safety data sheet can confirm whether a material is safe for laser cutting.
The process begins by designing a digital program in a CAD/CAM system that directs the laser cutter. This design file, typically a DXF or DWG file, outlines the desired shapes and dimensions of the parts to. The laser cutter, guided by the CNC system, then uses a concentrated beam of light to melt, burn, or vaporize the material along the programmed path. CNC cutting can also be effectively used for kitchen cabinet shutters, decorative panels, and partition walls to enhance kitchen interiors.
The result is a clean, smooth, and accurate cut that can accommodate complex shapes and small holes, all with minimal waste. Additionally, CNC cutting is utilized for creating visually appealing roof panels and false ceilings that can add artistic elements to interior designs.
Start Your Manufacturing Project with MakerVerse
MakerVerse is a platform for sourcing industrial parts. It provides instant access to a vetted supply chain and a full range of manufacturing technologies. With AI-powered quoting, order management, and fulfilment, MakerVerse helps with everything from initial prototypes to full-scale production.
Laser Cutting Design Tips and File Formats
1. Use the thinnest sheet possible. On average, material cost represents 37% of the cost of sheet laser cut parts. This percentage is larger for simple geometries. Calculating the minimum thickness that can withhold the load saves you money.
2. Ensure you select the appropriate material thickness for your project, as it affects both the engraving quality and the overall design integrity. Materials can range from 1 to 10 mm, and using materials that are too thin or too thick can compromise the design.
3. The flatness of the sheets partly depends on the raw material. Your part will require a rework if the flatness is more than 0.1mm (per meter).
4. Maintain a minimum distance between cutting lines to prevent material melting or potential fire hazards. This distance directly impacts the design’s effectiveness and the structural integrity of the final product. Ensure each line in your design is clearly defined and properly colored in your vector files to prevent errors during cutting.
5. Expect distortions at bent parts. The distortion will be more visible in thick sheets.
6. Keep a distance between the hole and the bending edge. The minimum distance from the edge of a hole to the adjacent edge of the blank should be at least stock thickness, but preferably it should be 1/2 to 2 times that.
7. Avoid some distortion by designing a window. Add a nonfunctional window at the bent corner if the distance from the hole to the edge is lower than recommended.
8. Expect misalignment before bending. Several alternatives can be considered:
- Drill the holes after forming. This is more expensive but provides excellent alignment.
- Use broad tolerances on the holes, or make one a slot, i.e., allow for misalignment if the function of the part permits.
- Include a pilot hole in the bottom of the U bend. This hole is located over a pin in the pad of the forming die that will consistently position the blank.
The thickness of the control stock is another requirement if your part needs close alignment. Although the material of close thickness tolerance commands a premium price, the extra cost may be more than offset by the savings realized by not having to perform the second operation.
9. Check the adequate number of threads for even minimum tightening ability. A rule of thumb for the minor thread diameter (tap-drill size) is that it not exceed twice the stock thickness for steel and brass and 1.5 times the stock thickness for aluminum, copper, and zinc.
10. Brush on both sides if parts are not bent. The bending tool marks affect your surface quality, and the surface can be brushed with lower quality and higher cost by hand.
11. Avoid tool marks. Define foiled sheets at your visual sides; the foil protects your part during machining and transport.
12. Define visual sides and no visual defects at the important surfaces. A perfect surface is not expected when not defined. Also it should be defined if no chips are allowed inside your laser cutted tubes.
13. Provide DXF files to save setup time. DXF files with your cut geometry to save time and prevent mistakes.
14. Keep the interior bend radii at least as large as the material thickness. To avoid distortion around the bend, parts should be designed with the interior bend radius to be the same size or greater than the material thickness.
15. Ensure the bend height is at least double the material thickness plus the bend radius. Small bend heights are more difficult to form and position in the press brake, which can result in deformation.
16. Use standard sheet thickness. For flat laser cutted parts, use the range between 1-10 mm. If the parts are bended, use 1-6 mm. Check in online shops if your raw material exists.
17. Avoid tiny cutting geometries. The minimum distance inside the geometry should be greater than the sheet thickness to minimize distortion caused by the beam.
Still Managing Suppliers the Old Way? See What It’s Costing You
Use our free, anonymous ROI calculator to estimate your savings with MakerVerse.
No account needed. No obligations. Just real numbers.
18. Leave some space between the cutting geometry. Space the cutting geometry at least two times the sheet thickness to avoid distortion.
19. Avoid the distortions at the edge. If holes are placed too close to the edge, the possibility of the hole tearing or deforming is higher, especially if the part later undergoes forming.
20. Use the same radii with consistent bend orientations to reduce costs. Inconsistent bend orientations and varying bend radii mean the part will be need to be reoriented more often, which requires more time from the machinistoperator.
21. If using a bending tool, be sure to leave enough room so it can access the corners. The tool needs to come 90° from the bending corner.
Safety Precautions for Laser Cutting
Laser cutting is a powerful and precise manufacturing process, but it comes with inherent safety risks that must be carefully managed to protect both operators and equipment. The intense laser beam used in a laser cutting machine can cause serious injuries, including eye damage and burns, and can also present a fire hazard if not handled correctly. To ensure a safe and efficient cutting process, it’s essential to follow best practices and safety protocols at every stage of your laser cutting projects.
Personal Protective Equipment (PPE)
Always wear protective eyewear specifically rated for the wavelength and power of your laser cutter. This is crucial for preventing eye injuries from direct or reflected laser energy. In addition, consider wearing gloves and protective clothing when handling materials that may have sharp edges after cutting.
Workspace Safety
Maintain a clean and organized work area around your laser cutter. Remove any flammable materials or debris from the vicinity of the laser cutting machine to reduce the risk of accidental fires. Never leave the laser cutter unattended during operation, as the high temperatures generated by the laser beam can quickly ignite certain materials. Always keep a suitable fire extinguisher within easy reach and ensure all users know how to operate it.
Machine Maintenance and Setup
Regularly inspect and maintain your laser cutting machine to ensure optimal performance and safety. This includes cleaning the laser head, checking for proper alignment, and verifying that all safety features—such as emergency stop buttons and beam guards—are functioning correctly. Proper alignment of the laser head is essential for both safety and achieving precise, high-quality cuts.
Selecting the right materials is a crucial part of safe laser cutting. Some materials, like PVC, can release toxic fumes when cut, posing health risks and potentially damaging the laser cutter. Always consult the material safety data sheet (MSDS) and manufacturer guidelines to confirm that your chosen material is safe for laser cutting. Be aware that different materials and material thicknesses may require adjustments to laser power and cutting speed to cut accurately and safely.
Environmental Considerations
Laser cutting can generate waste and consume significant energy, especially when working with thicker materials or large sheet metal parts. Dispose of scrap materials responsibly and consider recycling where possible. Efficient use of materials and energy not only supports environmental sustainability but can also help reduce higher costs associated with waste and excessive processing time.
Training and Procedures:Ensure that anyone operating the laser cutter has received proper training on both the machine and the specific materials being used. Follow all manufacturer instructions and established safety protocols. Regularly review and update safety procedures to reflect new equipment, materials, or project requirements.
By prioritizing safety at every stage of the laser cutting process—from selecting materials and preparing design files in CAD software to operating the laser cutter and handling finished parts—you can achieve optimal results while minimizing risks. Whether you’re working with thinner materials for intricate designs or thicker sheet metal for structural components, a commitment to safety ensures consistent results, protects your investment in equipment, and safeguards everyone involved in your laser cutting projects.
Get Started with CNC Laser Cutting
CNC laser cutting is a powerful and versatile manufacturing method that, when utilized effectively, can yield high-precision components and minimize production costs. It is, however, essential to understand the process intricacies, from the impact of material thickness on cost to the importance of the bend radius on part distortion. Kerf width typically ranges from 0.1 mm to 1.0 mm, depending on the material and cutting parameters. Dimensional tolerances are the allowable deviation in a part’s dimensions due to variations in the cutting process. Various finishing techniques can be applied to the metal surface to enhance properties like corrosion resistance and aesthetic appeal.
If you’re looking for design assistance – or need a high-quality CNC machining service, you can use the MakerVerse platform. Choose from a full range of materials and finishes for all your applications.
