How to Prepare Your File for Laser Cutting
Reading time: 5 minutes
Getting a perfect result from a laser cutter starts long before the machine is turned on. Whether you are a Melbourne-based designer or a small business owner, the quality of your vector file directly determines the precision of the final product. This guide explains the technical requirements to ensure your project is processed without errors.
The Importance of Vector Graphics
Unlike raster images (JPG, PNG), which are made of pixels, vector graphics are based on mathematical paths. A laser cutter follows these paths as a set of coordinates. If you provide a raster image, the machine cannot "see" a line; it only sees a collection of dots, which often leads to jagged edges or failed cuts.
For our workshop in Melbourne CBD, we require files in vector format. This allows us to scale your design to any size—up to our maximum working area of 900 x 600 mm—without any loss of quality. If your current design is a sketch or a photo, you can use our Layout Preparation service to convert it into a machine-ready file.
Defining Cut vs. Engrave
The laser machine operates in different modes: cutting (going all the way through the material) and engraving (removing a shallow layer of the surface). To tell the machine which is which, we use a colour-coding system. This is a standard practice in the Australian fabrication industry.
Typically, we use a "Red for Cut, Black for Engrave" system, but we are flexible as long as the distinction is clear. It is vital that your lines are not just coloured, but are actual paths. A thick black line that looks like a border but is actually a filled shape will be engraved as a solid block rather than cut as a thin line.
| Action | Line Colour (RGB) | Stroke Weight | Result |
|---|---|---|---|
| Cutting | Pure Red (255, 0, 0) | 0.001mm / Hairline | Complete through-cut |
| Engraving | Pure Black (0, 0, 0) | Filled or Thick | Surface marking |
| Scoring | Pure Blue (0, 0, 255) | 0.1mm | Shallow cut/line |
Stroke Weights and Path Closure
One of the most common errors we encounter is the "thick stroke" issue. For a laser to cut, the path must be a hairline. In software like Adobe Illustrator or CorelDRAW, set your stroke weight to the minimum possible value (e.g., 0.001 mm or 0.1 pt). If the line is too thick, the software may interpret it as an engraving area, resulting in a burnt edge rather than a clean slice.
Furthermore, ensure that all your paths are closed. A "closed path" is a shape where the start point and end point are exactly the same. If there is a tiny gap in your circle or square, the laser will stop at that gap, leaving your piece attached to the material sheet. We recommend using the "Join" tool in your software to verify all corners are sealed.
Managing Text and Fonts
When you send a file with active fonts, there is a risk that the machine software will replace your chosen typeface with a default one if the font is not installed on our system. This can ruin the aesthetics of your project, especially for professional office signage or personalised gifts.
To prevent this, always "Convert to Outlines" or "Create Outlines" for all text. This transforms your letters into vector shapes. Once converted, the text is no longer editable as a font, but it is guaranteed to look exactly as you intended. Please save a backup copy of your file with editable text before performing this step.
Avoiding Overlapping Lines
Double lines are a hidden enemy of laser cutting. If you have two identical paths sitting on top of each other, the laser will pass over that area twice. This not only wastes time but often causes the material to burn or melt, leaving charred edges on plywood or melted beads on acrylic.
Use the "Pathfinder" or "Weld" tools to merge overlapping shapes into a single outer silhouette. This ensures a smooth, single-pass cut that maintains the structural integrity of your piece. This is particularly important for complex designs with many interlocking parts.
Pre-Flight Checklist for Your File
- All elements are converted to vector paths (no raster images).
- Cut lines are set to Hairline/0.001mm thickness.
- All text has been converted to outlines/curves.
- No overlapping or duplicate paths.
- File is saved in .AI, .DXF, or .SVG format.
Melbourne Local Standards and Material Choice
In the Melbourne design community, we see a high demand for sustainable materials. When preparing your file, remember that different materials react differently to the laser. For instance, acrylic requires a very clean cut to avoid "frosting" on the edges, while plywood may require slight offsets to account for the kerf (the width of the material removed by the laser beam).
If you are unsure if your design is compatible with your chosen material, we recommend reading our guide on Choosing the Right Material for Your Project. This will help you decide whether a CO2 laser or a Fiber laser is more appropriate for your specific needs.
Once your file is ready, you can send it to us via email or visit our studio at 412 Collins Street. If you need professional assistance in refining your technical drawings, please contact us today to schedule a consultation.