Starting a laser cutting project can feel like a big leap—especially if you’re new to CAD or haven’t created a design file before. At Critical Laser, we work with people at every experience level, from engineers and fabricators to artists, small business owners, and first-time makers. If you feel unsure about designing your own part, you’re definitely not alone. The good news? You don’t need years of CAD experience to create a great design. You just need a few helpful guidelines.
This article will walk you through the foundational things to know when designing for laser cutting, all explained in simple terms. Whether you’re playing with a CAD program for the first time or sketching an idea on paper, these tips will help you get the best possible results.
You Don’t Need to Be a CAD Expert
A detailed and accurate design is the foundation of any good fabrication project. Without it, it’s like building a housThe biggest misconception we see is the belief that you must be a seasoned CAD designer to start a project. That couldn’t be further from the truth. Many people who come to us are working with digital design for the very first time. In fact, a huge portion of projects start as nothing more than a drawing, a screenshot, or a rough idea.
Here’s what you actually need to get started:
- a simple drawing
- rough dimensions
- or a general concept you can describe
That’s enough for us to help. If you do want to try building your own CAD file, you can absolutely do that too. Entry-level programs like Fusion 360, FreeCAD, or Illustrator make it relatively easy to produce a basic 2D file. And if at any point you’re unsure, our team can support you or convert your ideas into a production-ready file.
Start With a Simple 2D File
Laser cutting uses a 2D outline to tell the machine exactly where to cut. That means all you need to begin is a simple 2D drawing. Most common programs allow you to export files in formats like DXF, DWG, AI, SVG, or PDF. These formats give the laser everything it needs to start forming your project.
If you’re new to this, simplicity is your friend. Start with basic shapes or outlines. Don’t worry about making the file overly polished. Clean lines and clear geometry are the most important parts.
Use Real Dimensions
One of the most important things to understand in design is the need for accurate measurements. It’s very easy for someone new to CAD to create a shape that “looks about right” without realizing the scale is incorrect. That’s one of the main reasons designs need to be set to a real-world measurement system.
Always make sure your drawing is set to inches or millimeters before you begin. This ensures that what you draw is exactly what the laser will cut. A circle that looks like it’s about 2 inches wide on your screen may export at 1 inch—or 12 inches—if no units are set. Measuring accurately from the beginning prevents delays, rework, and wasted material.
Here’s how to think about it:
- Every line should reflect the actual size you want
- Your file should not be scaled up or down after exporting
- Measurements in your design become measurements in real metal
If accuracy is critical for a certain hole, slot, or dimension, adding that measurement clearly in your CAD file helps us verify everything before cutting begins.
Keep “Kerf” in Mind, But Don’t Stress About It
Kerf refers to the width of material the laser removes while cutting. Our fiber laser has a very thin kerf, but it still plays a role in extremely tight-fitting designs. For new designers, kerf is often confusing, but you don’t need to worry about calculating it manually. At Critical Laser, we automatically adjust for kerf based on the metal type, thickness, and your part’s specific geometry.
If any features in your design look too tight or unrealistic for fabrication, we’ll catch that before cutting anything. Our goal isn’t just to make a part—it’s to make a part that performs exactly the way you need it to.
Pay Attention to Hole Sizes
Holes are one of the most common areas where first-time designers run into trouble. When a laser cuts a hole, the heat and cutting process can shrink the final opening slightly compared to the size drawn in CAD. For general designs, this might not matter. But if your project uses bolts, screws, PEM inserts, or fasteners, the hole size becomes much more critical.
If you’re designing something that requires hardware, let us know ahead of time. We work with these specifications daily and can recommend or adjust hole sizes based on your hardware type and the metal thickness you’re using. This ensures everything fits the way you intend it to.
Don’t Forget Material Thickness
This is one of the most common things new designers overlook. Every metal has thickness, and that thickness impacts how parts fit together, how bends behave, and how joinery should be designed. The needs of a thin aluminum project are very different from those of a heavy mild steel bracket.
Material thickness affects things like slot width, tab size, bend radius, and structural performance. If you’re unsure which gauge or thickness suits your project, just ask. We can recommend the best option based on strength requirements, weight considerations, appearance, and budget.
Avoid Overly Complex Geometry
Laser cutters can create incredibly detailed shapes, but complexity comes with trade-offs—more cutting time, higher cost, and potentially weaker thin areas. When you’re new to CAD, simplicity is your best friend. Clean lines, smooth curves, and well-defined edges produce better results and are easier to fabricate.
Try to avoid:
- tiny interior cutouts
- extremely thin bridges
- overly intricate decorative areas
- micro-sized text
Here’s what you should keep in mind:
- simple shapes cut faster and more cleanly
- minimal detail helps maintain part strength
- bold, readable text cuts more reliably
Details are great, but clarity matters even more.
Ask Questions Early
When you’re new to laser cutting, it’s completely normal to feel unsure about certain parts of your design. The best thing you can do is ask questions early in the process. We’re here to help, and we’d rather guide you before cutting metal than fix issues later. If something in your design might cause trouble—tolerances, hole sizes, edge cases, bending considerations—we’ll point it out and offer simple solutions.
Why Work With Critical Laser
Designing for laser cutting is easier when you have the right partner. With over 25 years of experience, state-of-the-art equipment, and a team that genuinely cares about helping customers, Critical Laser makes each project smooth and stress-free. Whether you’re submitting a fully prepared DXF file or just bringing an idea to the table, we’ll help you choose the right material, prepare your design properly, and avoid common fabrication pitfalls.
Our shop in Lindon, Utah handles everything in-house—including cutting, bending, welding, pemming, and coatings—so you get consistent quality and dependable lead times. We love working with both seasoned professionals and first-time designers. Wherever you are in your experience level, we’re ready to help bring your idea to life.
You can learn more about how our fabrication process works on our Custom Metal Fabrication page.
And when you’re ready to begin your project, just reach out. You don’t need perfect CAD skills—you just need an idea. We’ll take it from there.