Key Takeaways

• All cut geometry must be on a single layer as closed, continuous paths (polylines).
• Remove duplicate lines, open paths, and stray points before uploading.
• Set your drawing to 1:1 scale in millimetres.
• Minimum hole diameter should equal the material thickness (or 1.5mm, whichever is greater).
• Separate bend lines onto a different layer — do not include them as cut geometry.

How to Prepare Your DXF File for Laser Cutting

A properly prepared DXF file is the difference between a smooth instant quote and a back-and-forth of questions before your order can proceed. This guide covers everything you need to know about preparing a laser-ready DXF, whether you're using AutoCAD, Fusion 360, SolidWorks, Illustrator, or an online design tool.

What is a DXF File?

DXF (Drawing Exchange Format) is the standard file format for 2D CAD geometry. It stores vector paths that describe the exact geometry of your part. The laser cutting machine reads this geometry and follows the paths with the laser beam. What you draw is exactly what gets cut — so accuracy in the file directly translates to accuracy in the part.

Step 1: Draw in Millimetres at 1:1 Scale

Set your CAD software to draw in millimetres, not inches or arbitrary units. Ensure your drawing is at 1:1 scale — a 100mm × 100mm square in your file should measure 100mm × 100mm when imported by the quoting software. Incorrect scale is one of the most common causes of quoting errors.

Step 2: Use a Single Layer for Cut Geometry

All lines that you want cut should be on a single layer. Name it "Cut" or "0" (the default layer). Do not mix cut lines with dimension lines, annotations, title blocks, or bend markers on the same layer. These will be interpreted as cut paths and will produce unwanted cuts in your part.

If your part requires bending, put bend lines on a separate layer labelled "Bend" or "Fold" and note the bend angle and direction in your order comments.

Step 3: Close All Paths

Every outline and internal cutout in your DXF must be a closed path — the start and end point must connect exactly. Open paths (gaps between line segments) prevent the quoting software from recognising the shape as a closed region and calculating the cutting length correctly. In AutoCAD, use PEDIT to join lines into polylines. In Fusion 360, use Sketch > Fix/Unfix to close open chains.

Step 4: Remove Duplicate Lines

Duplicate lines at the same position cause the laser to cut the same path twice, burning excess material and wasting cutting time you'll be charged for. Run OVERKILL in AutoCAD (or equivalent cleanup tools in other software) to detect and remove duplicates.

Step 5: Check Minimum Feature Sizes

The minimum hole diameter for laser cutting should be at least equal to the material thickness, or 1.5mm, whichever is larger. Features smaller than this may not cut cleanly or may warp from heat input on thin materials. Narrow slots should be at least 1× the material thickness wide.

Step 6: Verify the Part Outline

Before uploading, zoom in to every corner and junction in your DXF to confirm:

• All intersections connect cleanly
• No extra lines or arcs extend beyond corners
• Internal cutouts are fully inside the outer profile
• Text, dimensions, and annotations are on separate (non-cut) layers

Common Mistakes to Avoid

• Drawing in inches: Always use millimetres for Australian fabricators.
• Including the sheet outline: Only draw the part geometry, not the stock sheet boundary.
• Overlapping geometry: Where two parts share a common edge, keep them as separate closed profiles.
• Tiny radius fillets: Radii under 0.5mm may not resolve correctly — use a minimum 0.5mm internal radius.

Upload and Get an Instant Quote

Once your file is clean, upload it directly to the Ferracut instant quote tool. Select your material and thickness, and receive pricing in under 30 seconds.

Further Watching

• Make or Break Shop — Hands-on laser cutting tutorials and real-world material tests
• NYC CNC — In-depth CNC machining and fabrication walkthroughs

Get Your Parts Cut Today

Upload your DXF or DWG file to Ferracut and get an instant quote in under 30 seconds.