Design Guide for Flat Laser-Cut Parts
Useful information about supported vector formats, how to properly prepare your files for laser cutting, and capabilities of our laser cutting process.
Content
Laser Cutting Process
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Capabilities >Capabilities >
Format and Software
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Accepted Formats >Accepted Formats >
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Recommended CAD Software >Recommended CAD Software >
Preparing Your File
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Scale >Scale >
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Content >Content >
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Strokes >Strokes >
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Texts >Texts >
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Minimum Perforations >Minimum Perforations >
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Minimum Bridges >Minimum Bridges >
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Process features >Process features >
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Additional Considerations >Additional Considerations >
Process features
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Micro-Joint >Micro-Joint >
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Heat Deformation >Heat Deformation >
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Finishes >Finishes >
Additional Considerations
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Delivery Parts >Delivery Parts >
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Evaluation >Evaluation >
Click on the topics to access them.
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Laser Cutting Process
At LaserBoost, we perform sheet metal laser cutting using the latest cutting-edge technology from Trumpf™. Our expert team combines different types of gases and specific machine configurations for each material to ensure a quality cut.
We have the experience and machinery necessary to ensure manufacturing that aligns with your designs and delivers a superior quality finish.
> Laser cutting process capabilities
Our precision and maximum dimensions at a glance:
±0.20 mm*
Cutting Tolerance
3000 x 1500 mm
Size of our cutting formats
0.3 mm ~ 8 mm
Cutting Thickness Ranges
* Check here for manufacturing tolerances
or get more information about our laser cutting service.
Formats and Software
Accepted Formats
At LaserBoost, we work with vector files to ensure maximum precision in laser cutting. Below are the accepted formats and their requirements.
2D Format
.svg
⚠ SVG files may display different measurements than designed due to software version differences. Check and adjust them easily in our configurator.
⚠ PDF files must be vector-based, without images or text that hasn’t been converted to outlines. Only shapes created with vector paths are accepted.
3D Formats
.step or .stp
(Example in 3mm thickness)
Recommended CAD Software
There are many programs for CAD drawing, but the ones listed below are the most commonly used by our clients for laser cutting. All of them offer a free trial version.
CAD software for 2D laser cutting files
Autodesk Autocad™
The most widely used in the industry, a very professional tool, and a classic in 2D design.
Adobe Illustrator™
Perfect for beginners, with an easy-to-use interface and intuitive design.
QCad™
Free software with numerous design tools and a professional environment.
Inkscape™
Free software focused more on artistic vector drawing than on mechanical design.
CAD software for 3D laser cutting files
Autodesk Fusion360™
Perfect for beginners, free software with all the necessary tools to draw any geometry in flat or folded form.
SolidWorks™
The most widely used in the industry, a very professional tool, and a classic in 3D design.
Preparing Your File
The 7 basic points to have your parts ready for our configurator:
> Scale
Your part must be at the exact size you want it to be cut (1:1 scale). If you need a different size, adjust the height and width directly in the configurator. This option is available only for 2D formats. For other formats, adjust the dimensions in your CAD software.. Make sure your file is uploaded in millimeters (mm).
> Content
Your file must contain only the cutting lines and paths and a single part design per file. To get an accurate price for your parts, your design should be free from dimensions, notes, edges, and objects that shouldn’t be fabricated.
Each file must contain only one part. Multiple designs in a single file are not allowed; they must be submitted separately. LaserBoost reserves the right to cancel the manufacturing of files that do not comply with this rule.
> Strokes
Your designs should be free of open endpoints and intersections. Our process treats all lines in your design as cuts, so an open area will lack a complete cut, and an area with intersections will result in excess cuts.
Make sure your designs don’t contain any of these elements unless they are absolutely necessary.
> Texts
There are fantastic fonts out there, but we don’t have all existing typefaces on our cutting machines. To prevent any misinterpretation of your text, we need you to convert the text to outlines.
For more information on how to prepare signage and texts, visit our dedicated guide for this topic here.
> Minimum Perforations
For a proper cut, we require that all perforations have a minimum diameter.
Thickness t (mm)
Minimum Diameter d (mm)
0.5
0.5
0.8
0.5
1.0
0.5
1.2
0.8
1.5
0.8
2.0
1.5
2.5
2.0
3.0
2.5
4.0
2.5
5.0
3.5
6.0
4.0
8.0
5.0
During laser cutting, in materials with protective film, if there are small geometries, high cutting density, or, in general, geometries close to each other at a distance of less than 8 mm, the film may not adhere properly or may even be absent in those areas.
For aluminum and copper, the hole diameter (d) must be equal to the sheet thickness to ensure perforations without tapering. If these dimensions are not met, the customer will be responsible for extracting the internal scraps from holes or small shapes in these materials.
> Minimum Bridges and Distance to the Nearest Vertices
To avoid burns or irregularities in the narrow areas of the part, we need them to meet a minimum distance. This also applies to the minimum distance between the cutouts and the outer edge of the part.
Thickness t (mm)
Minimum Space s (mm)
0.5
0.5
0.8
0.5
1.0
1.0
1.2
1.0
1.5
1.5
2.0
1.5
2.5
1.75
3.0
2.1
4.0
2.8
5.0
3.5
6.0
4.2
8.0
5.6
During laser cutting, in materials with protective film, if there are small geometries, high cutting density, or, in general, geometries close to each other at a distance of less than 8 mm, the film may not adhere properly or may even be absent in those areas.
For aluminum and copper, the distance (s) must be equal to the sheet thickness to ensure perforations and shapes without tapering. If these dimensions are not met, the customer will be responsible for extracting the internal scraps from holes or small shapes in these materials.
Visible face and finish direction
The visible face of the part is the one that will have the selected finish and the one that will be facing up during the cutting process. If the finish is double-sided, there is no difference. In 2D files (flat parts), it corresponds to the visible side in the document and in the online configurator. In 3D files, it is also the default visible face; if you prefer the other side, please indicate it in the text box of the configurator for that part.
In the following example, the default Visible Face is highlighted in orange.
2D
3D
The direction of finishes with orientation in flat files will always be horizontal ↔ according to the orientation of the image shown in the configurator. In 3D files, the most suitable direction for manufacturing will be selected. An example of finishes with orientation is the brushed finish. If you need a specific finish direction in either case, please indicate it in the comments section within the parts configurator.
Laser cutting is always perpendicular to the surface of the part, so it is not possible to make angled perforations or cuts on the edge or thickness of the material. All perforations must be designed following this principle.
Process features
Microjoint (Micro-union or Micro)
The microjoint is a small connection that keeps the part attached to the sheet during the cutting process, preventing movement or falling into the waste area. It is necessary depending on the geometry and size of the part.
They are almost imperceptible and do not affect the application of the part, with sizes ranging from 0.1 mm to 1 mm depending on the material thickness. If you prefer to avoid these joints in certain areas, please indicate it in the configurator. Complete removal of the microjoints is possible for an additional cost; contact us for more details
Heat Deformation in Laser Cutting
Laser cutting is a precise technique for manufacturing parts. However, if a design has a high cutting density, elevated temperatures can be generated during the process. These temperatures might lead to deformations in the part, compromising its quality and functionality. Therefore, it’s important to consider the distribution of cuts and adjust the design to avoid excessive heat concentrations.
At LaserBoost, we employ different cutting strategies to deal with this effect. Nevertheless, in extreme cases, the effect might still be visible. One way to reduce this effect, especially common in grid patterns, is to space out the holes. Additionally, this approach can lead to cost savings for your part.
Finishes
For details on our finishes, check our Finishes Guide. You’ll find useful information and sample photos of all available finishes.
Additional Considerations
Delivery of Parts, Not Scrap
At LaserBoost, we only deliver the requested parts, without including interior scraps or exterior waste. This is due to material optimization and the cutting strategy followed during the manufacturing phase, always aiming to ensure minimal material waste and better cutting quality. Interior scraps will only be left in designs where their removal is impossible without damaging the part or its geometry.
Evaluation of Additional and Special Requests
Any comments or special needs provided with the order will be evaluated by our technical department. If the request involves additional adjustments in the manufacturing process, it may incur an extra charge, which will be communicated before proceeding with production.
Heat deformations
Laser cutting generates heat that can cause warping in long, narrow parts, fine features, or thicknesses not suitable for the design. Although we recommend following our design guidelines, some deformations may be unavoidable depending on the geometry. LaserBoost is not responsible for these effects.
| ChangeLog | ||
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Date |
Change |
Description |
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17.Feb.2025 |
Publication |
General modifications have been applied, including the addition of new sections and the update of values in the tables. |
Any questions? LaserBoost’s technical team is at your disposal to help you with your design and validate its productive potential.
Contact us here.
About User Guides, Tolerances, and Production Capabilities of LaserBoost Service
It is possible to correctly manufacture parts that do not meet the capacities announced here. However, LaserBoost cannot guarantee the correct result of cutting and/or bending if the specifications mentioned on our website are not met. If a design does not meet any of the announced tolerances, capacities, or limitations, it can be produced by LaserBoost at the customer’s risk. You can validate the proper producibility of your design prior to placing an order by contacting our technical team at info@laserboost.com.
For more information about using our platform, you can visit our Terms and Conditions of Service.
