DFM Guide · Laser Cutting

Tight kerf.
Clean edge.
Design for it.

Laser cutting produces precise cuts with narrow kerf and clean edges. Specific design considerations: kerf width, hole minimum, tab/slot fit, lead-in/lead-out for clean entry.

Free DFM Review Laser cutting service

01 · Material capability

What we cut.

Mild steel

Up to 20 mm

4kW fiber laser cuts mild steel up to 20 mm thickness. Faster speeds at thinner sheet.

Stainless 304/316L

Up to 12 mm

Stainless cutting requires nitrogen assist gas (no oxide on edge). Up to 12 mm typical.

Aluminum 5052/6061

Up to 8 mm

Aluminum reflective — fiber laser cuts efficiently. 6 mm 5052 typical thickness.

Brass / copper

Up to 6 mm

Reflective metals — challenging but cuttable. Fiber laser preferred over CO2.

Titanium

Up to 8 mm

Titanium with argon assist gas. Aerospace standard, premium cost.

Galvanized steel

Up to 6 mm

Zinc coating affects edge. Acceptable for most industrial.

02 · Design rules

Laser cutting DFM.

Kerf width

0.1-0.3 mm

Laser kerf 0.1-0.3 mm wide. Allow for kerf when designing tight-fitting features.

Min hole

≥ thickness

Holes smaller than material thickness become slots. Specify ≥ thickness for round holes.

Min slot width

≥ thickness

Slots narrower than material thickness become impossible. ≥ thickness required.

Edge to feature

2× thickness

Features within 2× thickness of edge may distort. Place ≥ 2× thickness from cut edge.

Tab and slot

0.05 mm interference

Tab in slot fit: tabs slightly larger (kerf-compensated) for press fit. We adjust automatically.

Sharp corners

R0.5 minimum

Sharp internal corners cause heat accumulation. R0.5 minimum, R1 better.

03 · Edge quality

What edge to expect.

Laser cut edge: nearly square (slight bevel possible), Ra 3.2-12.5 µm depending on material/thickness/parameters. Generally acceptable for most applications.

Heat affected zone (HAZ): 0.1-0.5 mm zone of changed properties next to cut. Usually invisible. May affect heat-sensitive subsequent welding.

Burr: small burr possible on bottom surface from material expulsion. Specify deburr if mating surface or critical. Standard deburr included for most parts.

Surface finish: top surface mostly preserved; bottom surface sees melted material and gas blow. Inspection both sides before subsequent operations.

04 · Special techniques

Advanced laser cutting.

Lead-in / lead-out

• Laser entries from outside the part shape
• Prevents pierce mark on visible edge
• Standard automatic addition to programs
• 1-2 mm lead-in length typical

Bridges and tabs

• Small bridges hold parts in sheet during cutting
• Allows multi-part nesting without parts falling out
• Hand-broken after cutting
• Specify bridges if needed; default is full cut

FAQ

CO2 vs fiber laser difference?

CO2 laser: cuts wood, acrylic, fabrics; medium for thin metal. Fiber laser: dominant for metal cutting, faster, better edge quality. Our fiber lasers handle metals up to 20 mm steel.

Tolerance on laser cut parts?

±0.1 mm standard. ±0.05 mm achievable with specific setup. For mating features requiring tighter tolerance, post-cut machining.

Material thickness limits?

Practical: depend on laser power. 4kW: 20 mm steel, 12 mm stainless. Higher powers extend thickness. Above ~25 mm typical for plasma or waterjet.

Cost vs other methods?

Laser fastest for thin sheet (under 6 mm). Plasma cheaper for thick steel (above 12 mm). Waterjet for any material/thickness, slow. Choose per material+thickness combo.

Setup time and cost?

Laser cutting low setup — file uploaded, cuts run. Per-piece cost low, even at small quantities. Often economical for prototype 1-piece quantities.

Reflective metals OK?

Aluminum, copper, brass cuttable with fiber laser. CO2 laser struggles with reflective metals. Brass and copper challenging at thicker sections.