Key Takeaways

• Always draw in 2D at 1:1 scale with units set to millimetres before exporting.
• Close all open paths — this is the #1 cause of rejected files and incorrect parts.
• Use a single layer for cut geometry and remove all annotations, hatching, and title blocks.
• Run OVERKILL (AutoCAD) or equivalent to eliminate duplicate lines before export.
• Export as DXF R14 or 2000 format from AutoCAD; use the flat pattern export in Fusion 360.

How to Prepare DXF and DWG Files for Laser Cutting: The Complete Guide

Why File Preparation Matters

The most common cause of delayed orders, incorrect parts, and unexpected costs in laser cutting is not the machine — it's the file. A poorly prepared DXF or DWG file can result in open paths, incorrect scaling, missing features, or unnecessary piercing cycles that inflate your quote and your lead time.

This guide walks through exactly how to prepare a clean, production-ready laser cutting file from any major CAD application. Follow these steps and your parts will come back accurate, on time, and priced correctly.

Step 1 — Draw in 2D at 1:1 Scale

Your file must represent the part at true, real-world size. Set units to millimetres before you begin. If exporting from a 3D CAD package (SolidWorks, Fusion 360, Inventor, CATIA), create a flat pattern of the part before exporting. The laser cutter works in 2D and cannot interpret 3D geometry directly.

Step 2 — Use a Single Layer for Cut Geometry

Place all cut lines on a single, dedicated layer named clearly (e.g. "CUT" or "PROFILE"). Remove all other layers before exporting — including dimension layers, annotation layers, construction geometry, title blocks, and hatch or fill layers.

Step 3 — Close All Open Paths

Every profile must be a closed polyline. Open paths are the #1 cause of file rejection and incorrect quoting. In AutoCAD, use the PEDIT command with the Join option. In Fusion 360 or SolidWorks, verify sketch profiles are fully closed before creating the flat pattern.

Step 4 — Remove Duplicate Lines

Overlapping or duplicate lines cause double-cutting, which burns material, wastes time, and can distort delicate features. In AutoCAD, run OVERKILL to automatically detect and remove duplicates. In other packages, audit your sketch for coincident lines before export.

Step 5 — Check Minimum Feature Sizes

Laser cutting has physical limits. As a rule of thumb, holes should be no smaller than the material thickness, and bridges (the narrow sections between features) should be at least 1.5× the material thickness to avoid burning through. If your design has very fine detail, confirm with your cutting service before ordering.

Step 6 — Export in the Right Format

For AutoCAD: export as DXF R14 or DXF 2000. These are universally supported. Avoid newer DXF versions or DWG unless your cutting service specifically requests DWG. For Fusion 360: use File → Export → DXF from the sketch or flat pattern. For SolidWorks: save as DXF from the flat pattern drawing. For Illustrator or Inkscape: export outlines only as DXF (no fills, no raster elements).

Common Mistakes to Avoid

• Wrong units — if your part comes back 25× too large or small, units were set to inches instead of mm (or vice versa)
• Spline curves — convert splines to polylines with a suitable tolerance before export; some cutting machines cannot interpret raw splines
• Text as outlines — if you want text cut, convert it to outlines/curves first
• Hidden layers — layers that are turned off in your CAD file may still export and get cut

Get Your Parts Cut Today

Ready to put this into practice? Upload your DXF or DWG file to Ferracut and get an instant quote in under 30 seconds — no emails, no waiting, no minimum order.

Step 7 — Check Your File Before Submitting

Before uploading, do a final visual check by opening the exported DXF in a free viewer such as Autodesk DWG TrueView:

• Does the overall part outline look correct?
• Are all internal features present and correctly positioned?
• Are there any stray lines outside the intended part boundary?
• Are text or dimensions accidentally included?

A 60-second visual check at this stage can prevent a 48-hour delay in production.

Common File Errors and How to Fix Them

My quote looks much higher than expected

Usually means duplicate lines (the system calculates double the cutting length) or the file was submitted at the wrong scale. Re-check your export settings and resubmit.

Some features are missing from my quote preview

Missing features are almost always open paths. Go back to your CAD file, close the open loops, re-export, and resubmit.

My part looks the right shape but the scale seems off

Check your CAD file units. If geometry was drawn in inches but exported without converting to millimetres, the part will appear at 1/25.4 of its intended size.

Getting Your Quote

Once your file is prepared, head to Ferracut's instant quote page, upload your DXF or DWG, select your material and thickness, and you'll have an accurate price in seconds. No account needed, no minimum order, and no follow-up calls required unless you want them.

Frequently Asked Questions

Do I need to nest my parts before submitting?

No. Submit each individual part as its own file. Ferracut's system handles nesting automatically to optimise material usage and minimise your cost.

Can I submit multiple parts in a single file?

Yes, for simple orders. Separate them clearly with space between each part profile and note the quantities required for each in the order comments.

What if I don't have a CAD file?

If you have a PDF, hand sketch, or photo of the part, contact Ferracut's team. Simple geometry can often be recreated from a reference drawing.

Can I send an AI or EPS file from Illustrator?

Ferracut's quoting system requires DXF or DWG format. Export from Illustrator via File > Export > Export As > DXF, then verify scale in a DXF viewer before submitting.