Slide 001: Design File Preparation for Laser Cutting

Slide Visual

Slide Overview

This slide covers the design file preparation workflow from concept to laser-ready file. Proper file setup prevents wasted material, machine errors, and frustration. Students learn color mapping conventions, common file errors, and the critical difference between vector and raster elements.

Instruction Notes

Design Software Options

Any vector design tool can produce laser-ready files: - Inkscape (free, open-source) — SVG native, exports DXF - Adobe Illustrator (professional) — AI native, exports SVG, DXF, PDF - CorelDRAW (professional) — integrates directly with many laser controllers - Fusion 360 / SolidWorks (CAD) — exports DXF for precision mechanical parts - LightBurn (laser-specific) — both design and laser control in one application

Color Layer Convention

Most laser software uses colors to separate operations:

Color	Operation	Mode	Typical Use
Red (RGB: 255,0,0)	Cut	Vector cut	Through-cutting outline
Black (RGB: 0,0,0)	Engrave	Raster engrave	Filled areas, images, text
Blue (RGB: 0,0,255)	Score/Mark	Vector engrave	Lines, outlines, fold lines
Green (RGB: 0,255,0)	Secondary cut	Vector cut	Internal cutouts

Important: Colors must be EXACT RGB values. A "close to red" color (like 250,5,5) will be treated as a separate layer, not as the red cut layer.

Common File Preparation Errors

1. Open paths — Lines that do not form closed shapes cannot be cut as outlines. The laser software may skip them or produce unexpected results. Always "close path" or "join nodes" for cut outlines.

2. Duplicate lines — Two identical lines stacked on top of each other cause the laser to cut the same path twice, resulting in over-burned edges, excessive charring, and wasted time. Check for duplicates by selecting all and looking for overlapping objects.

3. Hairline vs. filled strokes — For cutting, strokes should be set to "hairline" or the minimum width. Thick strokes may be interpreted as filled regions (engraved) rather than cut paths.

4. Embedded raster images — If a vector file contains embedded raster images, these will be engraved (raster mode) while vector elements are cut. This is valid for combined jobs but can be surprising if unintended.

5. Units mismatch — Design in the correct units (millimeters). If the design software is set to inches and the laser software expects mm, the design will be scaled 25.4x too large or too small.

File Format Selection

• SVG: Best for general use, preserves layers and colors, widely compatible
• DXF: Best for CAD-derived precision parts, pure vector, no color fills
• AI: Best when designing in Illustrator, preserves all layer and color data
• PDF: Versatile, can contain both vector and raster, good for combined jobs

Key Talking Points

1. Color-code your design from the start — it is much easier to assign colors during design than to fix them later in the laser software
2. Always check for duplicate lines and open paths before sending to the laser — these are the top two file errors that cause wasted material
3. Design in millimeters and verify dimensions match your material before cutting

Learning Objectives (Concept Check)

• [ ] Students can prepare a laser-ready design file with correct color coding for cut, engrave, and score operations
• [ ] Students can identify and fix the five most common file preparation errors
• [ ] Students can select the appropriate file format for their design workflow

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Last Updated: 2026-03-19