Short answer: Send a vector DXF or SVG drawn at 1:1 scale in inches or millimeters, with every cut line a closed path and no duplicate lines. Convert text to outlines, delete dimensions and borders, and put engraving on its own color or layer. Note in your order what is cut and what is engraved: we treat every line as a cut unless you tell us otherwise.

Key facts

  • Formats: DXF or SVG (vector). JPG and PNG must be traced first.
  • Scale: 1:1, real finished size. SVG defines 1 in. as 96 px; files made on a different assumption open at the wrong size.
  • Cut lines: closed paths, stroke only, no fill. Laser makers use about 0.001 in. (0.072 pt) or "hairline" strokes.
  • Engraving: filled shapes on a separate color or layer.
  • Spacing: at least the sheet thickness between parts.
  • Kerf: draw to finished size; the laser removes about 0.006 to 0.010 in. and we compensate.

Which file format should you send?

DXF or SVG if you can. Both are vector formats: they describe lines and curves mathematically, which is what a laser follows. Photos and screenshots (JPG, PNG) are pixels and can't be cut directly; they have to be traced first (how to convert an image to SVG).

  • Adobe Illustrator: File > Export > Export As, then SVG or AutoCAD Interchange File (DXF).
  • Inkscape: saves SVG natively; File > Save As, then Desktop Cutting Plotter (AutoCAD DXF R14) for DXF.
  • Fusion: right-click a sketch and choose Save as DXF.
  • AutoCAD: DXF natively.
  • CorelDRAW: Export as DXF or SVG.

Draw at 1:1 scale and check the units

Draw the part at its real, finished size. Scale is the most common file problem we see. Some DXF files don't say whether they're in inches or millimeters, so a 4 in. part can open as 4 mm, or a 100 mm part as 100 in.

SVG has its own trap. The SVG and CSS standards fix 1 inch at 96 pixels (and 72 points). If a program writes its drawing in pixels or points without real units, another program may read it at a different ratio and your part arrives at about 75% or 133% of its size. To avoid both problems:

  • Set document units to inches or millimeters before you start drawing.
  • In Inkscape, check Document Properties: the display units and the scale should match what you designed in.
  • Put the overall size in your order notes ("part is 12 x 8 in.").
  • Open the file in our laser file checker, which shows the size it reads.

Make every cut line a closed path

A part's outline should be one continuous path that ends where it starts. If it's made of separate segments that only look connected, the laser may cut them in an odd order, or a tiny gap may leave the part attached to the sheet. In Illustrator, select the endpoints and use Object > Path > Join; in Inkscape, select the two end nodes and click Join selected nodes; in AutoCAD, use JOIN or PEDIT. The file checker flags open paths.

Delete duplicate and overlapping lines

Two lines stacked exactly on top of each other look like one, but the laser cuts both. That doubles the heat on that edge: a wider, melted cut and sometimes a frosted edge. Duplicates come from paste-in-place, from two parts that share an edge both being drawn in full, or from an export that includes both a shape and its outline. Use OVERKILL in AutoCAD, or select all and check the object count. If two parts share an edge on purpose to save material, say so in your notes.

Convert text to outlines

Live text depends on the font being installed on the computer that opens the file; without it, the text switches to a default font. Convert text to paths first: Type > Create Outlines in Illustrator, Path > Object to Path in Inkscape, Convert to Curves in CorelDRAW, EXPLODE (or TXTEXP) in AutoCAD.

Remove everything that isn't a cut or engrave

Delete construction lines, center marks, dimensions, title blocks, borders, and notes from the drawing. Put notes in your order instead. Hidden layers and stray points can still export, so re-open the exported file and check it.

What stroke width should cut lines be?

Thin, with no fill. Laser makers' drivers use stroke width to tell cuts from engraving: Epilog's setup guide calls for a 0.001 in. (0.072 pt) line in Illustrator and a hairline in CorelDRAW, and Trotec's calls for 0.001 mm. The laser follows the center of the path either way, so the width doesn't change the cut; it just keeps cut lines from being read as engrave areas. In Inkscape, View > Display Mode > Visible Hairlines keeps such thin lines visible at any zoom.

  • Cut lines: thin strokes, no fill, one color (red is the common convention).
  • Fill engraving: filled shapes, on a separate color or layer.
  • Line engraving (scored lines that don't cut through): its own color or layer.

Important: we treat every line in a drawing as a cut unless you tell us otherwise. If part of your design is engraving, put it on its own color or layer and note it in your order, for example "red is cut, black fill is engrave."

How far apart should parts be?

You can send one part per file, or many parts on one drawing. If you lay out several:

  • Keep at least the sheet thickness between parts, more around fine detail, so heat from one cut doesn't distort its neighbor.
  • Don't squeeze them together to save material. We nest parts on the sheet ourselves.
  • Tell us the quantity of each part instead of copying it many times in the file.

Check the design will survive cutting

Look for features smaller than the sheet thickness: tiny holes, thin bridges, delicate tips (smallest detail you can laser cut). For tab-and-slot parts, size slots from the real sheet thickness (tab and slot design). You don't need to offset for kerf; we handle it. If you already have, say so (laser kerf).

Quick checklist

  1. DXF or SVG, 1:1 scale, units confirmed.
  2. All cut lines closed, no duplicates.
  3. Text converted to outlines.
  4. No dimensions, borders, or construction lines.
  5. Engraving on its own color or layer, and noted in the order.
  6. Parts spaced at least the sheet thickness apart.

Then upload your drawing for an instant price. If you only have a sketch or an idea, describe it and we can help with the design.

Questions

Can I send a PDF or AI file?

Yes, the upload accepts PDF, AI, EPS, and CDR as well, as long as the artwork inside is vector. DXF and SVG are still the most reliable because they open the same way everywhere.

Does stroke width matter for laser cutting?

Not to the cut itself: the laser follows the center of the line. Thin strokes (about 0.001 in. or hairline) keep cut lines from being mistaken for filled engrave areas.

Should my file be in the color of the acrylic?

No. Colors in the file only tell cut, line engrave, and fill engrave apart. Pick the acrylic color when you order.

Why does my SVG open at the wrong size?

Usually the file was saved in pixels or points without real units, and the program opening it assumes a different number per inch (the SVG standard uses 96 px per inch). Set the document units to inches or millimeters and re-export.

Sources