Getting a DXF file wrong is the single most common reason laser cutting orders get delayed. Whether you're designing in Fusion 360, SolidWorks, AutoCAD or Inkscape, there are a handful of rules every file must follow before it's ready to cut. This guide covers all of them.
What is a DXF File?
DXF (Drawing Exchange Format) is a CAD file format developed by Autodesk. It describes geometry — lines, arcs, splines and circles — in a way that laser cutting machines can read directly. Unlike a PDF or image, a DXF file contains precise mathematical coordinates that the laser follows to cut your part.
When you upload a DXF to QuickCut, our system reads the geometry to calculate cut length, detect bends, and price your job automatically. A clean file means an accurate quote. A messy file means errors, delays or incorrect parts.
Rule 1: Export as a Flat Pattern
Laser cutting is a 2D process. Your DXF must represent the flat, unfolded shape of your part — not a 3D view or a drawing with dimensions and title blocks.
- Fusion 360: In Sheet Metal, use Flat Pattern → right-click → Save as DXF
- SolidWorks: Sheet Metal tab → Flatten → File → Save as DXF
- AutoCAD: Draw your flat outline on layer 0, delete all dimensions and text, then Save as DXF
- Inkscape: Draw in mm, ensure the document size matches your part, then Save as DXF (R14 format)
In Fusion 360, export the flat pattern directly — do not sketch over it or re-draw it. Exporting from the flat pattern itself preserves bend lines as separate layers, which QuickCut uses to calculate bending costs automatically.
Rule 2: One Part Per File
Each DXF file should contain exactly one part. If you need 10 brackets, upload one bracket DXF and set the quantity to 10. Do not nest multiple parts into a single file — our system will read the whole file as one shape and price it incorrectly.
Rule 3: Close All Contours
Every outline and internal cutout must be a closed loop. A gap as small as 0.01mm will cause the laser to either skip the contour entirely or produce an open cut. This is the most common DXF error.
To check for open contours:
- AutoCAD: Select all geometry → OVERKILL command to merge overlapping lines, then BOUNDARY to test if regions close
- Inkscape: Select all paths → Path → Union — if shapes don't merge cleanly you have gaps
- Fusion 360: Sketch analysis will highlight open loops in red before you extrude
Lines that visually look connected are often not — they end 0.05mm apart. Zoom in to 1000% in your CAD tool to check junctions, or use a "snap to endpoint" tool when drawing.
Rule 4: No Duplicate Lines
Duplicate overlapping lines cause the laser to cut the same path twice, which widens the kerf, overheats the material and produces a rough edge. Run AutoCAD's OVERKILL or Inkscape's Path → Clean Up Document before exporting.
Rule 5: Use the Correct Scale (1:1 in Millimetres)
South African fabricators — including QuickCut — work in millimetres. Your DXF must be at 1:1 scale. A 100mm × 50mm part should read as exactly 100mm × 50mm in the file.
If you design in inches, convert before exporting: 1 inch = 25.4mm. Most CAD packages have a unit conversion option in the export dialog.
Rule 6: Minimum Feature Sizes
Laser cutting has physical limits on how small features can be:
- Minimum hole diameter: equal to the material thickness (e.g. 3mm hole in 3mm steel)
- Minimum slot width: 1.2× material thickness
- Minimum bridge / web: 2× material thickness between two cutouts
- Minimum outside radius: no limit — laser can cut sharp external corners
Features smaller than these limits will either burn away or produce a distorted edge. If your design requires them, contact us — thinner material or a different process may work.
Rule 7: Separate Bend Lines onto Their Own Layer
If your part has bends, include the bend lines in the DXF on a separate layer named BEND or BENDS. QuickCut's quoting system reads this layer to detect bending operations and include them in your price automatically.
Bend lines should run the full width of the part at the exact position of each bend. Do not include bend annotations, arrows or text on this layer — geometry only.
Final Checklist Before Uploading
- ✅ Flat pattern only — no 3D views, dimensions or title blocks
- ✅ One part per file
- ✅ All contours closed
- ✅ No duplicate geometry
- ✅ Scale 1:1 in millimetres
- ✅ Minimum feature sizes respected
- ✅ Bend lines on separate BEND layer (if applicable)
DXF files from any CAD package. If your software exports a non-standard DXF variant and you're seeing errors, email info@quickcut.co.za with your file and we'll advise on the best export settings.
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