What are common problems to look for in my files?

Before you upload your files to SendCutSend, make sure to check for these common problems.

  • Duplicate paths 
    • Duplicate paths in your 2D vector file (.dxf, .dwg, .eps, or .ai format) will be rejected by our automated system since the laser cannot recognize or cut them. Be sure to go through the geometry in your file and make sure that there is only one of each cut path needed. This is especially important in 2D design software, which is another reason why we recommend you design your part using a CAD program like Fusion360 or SolidWorks.

  • 3D file considerations
    • If you plan to upload a .step or .stp format file, ensure your design meets our 3D File Guidelines.

  • Small geometry
    • Geometry on laser cut parts should be at least 50% of the material thickness. Holes or interior geometry that are smaller than 50% the thickness of your material are unlikely to be cut accurately by the laser. 

As an example, if your material is 0.100” thick, the smallest hole you could expect to cut would be 0.050” in diameter. A safe rule of thumb would be to keep all geometry greater than 1/2 material thickness, and no smaller than .015″.

For additional information on minimum geometry and part sizes, take a look at our Min/Max charts and small geometry considerations guide.

  • Shared Geometry
    • Common-line or nested cutting (as shown in the drawing below) can lead to imprecise parts since it doesn’t account for our beam-width or kerf. Depending on the material, the gap between the parts will vary from .006″ to .012″ or more.
    • If you want to design a slip fit for mating parts, take a look at our guide.

If you lay out your parts as shown below on the right, we’ll be able to send you parts that will be much more precise. Additionally, they won’t have manufacturing imperfections like pierces and “lead-in” marks that we use to start the cut.

  • Can I receive the “drop outs” or internal parts? 
    • Our production process is mostly automated, so we cannot send drop-through or scrap pieces with your order. Those sections will be destroyed or lost in our process.  If there is a second piece you would like it is best to submit it as a separate file to be cut.  

  • Nested Parts
    • Please upload each part as an individual file. We will arrange your parts in a way that maximizes efficiency and reduces material waste. This process is known as “nesting”. 
    • Designers are often tempted to “pre-nest” their design, thinking that it will speed up the production process. However, this is more likely to complicate the cutting and impede our process. If you want to cut multiple copies of a single object, don’t crowd your design. Simply upload a drawing with a single part and adjust the quantity in your cart.

In Summary

What are common problems to look for in my files?

We see many common issues in uploaded files. We compiled a list of problems and tips that you can reference before uploading your files.
10 Common Reasons Your Design is Failing SendCutSend Preflight

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Upload your CAD design or use our parts builder and get instant pricing on your custom laser cut parts, all delivered to your door in a matter of days.

We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild, G30

SKUSO-440-8
Thread Size4-40 x .250″
Hole size in sheet (+0.003/-.0.000).168″
Minimum sheet thickness0.040″
Maximum sheet thickness.125″
Fastener materialSteel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..345″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Length.250″
Aluminum material ranges (5052, 6061, 7075)0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)0.048″-0.119″

We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Passivated

Stainless Steel: 304, 316

SKUSO4-440-8
Thread Size440
Hole size in sheet (+0.003/-.0.000).166″
Minimum sheet thickness0.04″
Maximum sheet thickness.125″
Fastener material400 Stainless Steel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole. Example shown with x2 of the same hardware..313″
Recommended panel materialStainless Steel
Coating typePassivated
Length.250″
304 Stainless Steel material ranges0.048″-0.125″
316 Stainless Steel material ranges0.060″-0.125″