Laser tube cutting design guidelines

For the quickest and most efficient tube cutting experience, please read our guidelines below and download the correct profile before uploading your first file. 

Download a tube profile

Before you design, you’ll need to find the correct profile to download.

6061 T6 Aluminum Tube

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.062"
Diameter:
1" x 1"
SKU:

6061-REC-100-100-062

Wall Thickness:
0.125""
Diameter:
3" x 3"
SKU:

6061-REC-300-300-125

Rectangle tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.062"
Diameter:
2" x 1"
Max Length:

6061-REC-200-100-062

Wall Thickness:
0.125"
Diameter:
3" x 1"
Max Length:

6061-REC-300-100-125

A500/A513 Mild Steel

round tubing
Wall Thickness​
Diameter
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.095"
Diameter:
1.75"
SKU:

CR-RND-175-095

Wall Thickness:
0.120"
Diameter:
1.75"
SKU:

CR-RND-175-120

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.120"
Diameter:
2" x 2"
SKU:

HR-REC-200-200-120

Wall Thickness:
0.188""
Diameter:
2" x 2"
SKU:

CR-REC-200-200-188

Rectangle tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.188"
Diameter:
4" x 2"
Max Length:

CR-REC-400-200-188

304 Stainless Steel

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
0.120"
Diameter:
1" x 1"
SKU:

304-REC-100-100-120

6061 T6 Aluminum Tube

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
1.58mm
Diameter:
25.4mm x 25.4mm
SKU:

6061-REC-100-100-062

Wall Thickness:
3.2mm
Diameter:
76.2mm x 76.2mm
SKU:

6061-REC-300-300-125

Rectangle tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
1.58mm
Diameter:
50.8mm x 25.4mm
Max Length:

6061-REC-200-100-062

Wall Thickness:
3.2mm
Diameter:
76.2mm x 25.4mm
Max Length:

6061-REC-300-100-125

A500/A513 Mild Steel

round tubing
Wall Thickness​
Diameter
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
2.41mm
Diameter:
44.45mm
SKU:

CR-RND-175-095

Wall Thickness:
3.05mm
Diameter:
44.45mm
SKU:

CR-RND-175-120

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
3.05mm
Diameter:
50.8 x 50.8mm
SKU:

HR-REC-200-200-120

Wall Thickness:
4.78mm
Diameter:
50.8 x 50.8mm
SKU:

CR-REC-200-200-188

Rectangle tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
4.78mm
Diameter:
101.6 x 50.8mm
SKU:

CR-REC-400-200-188

304 Stainless Steel

Square tubing
Wall Thickness​
WxH
SKU
DXF & STEP Profiles
Specs
Wall Thickness:
3.05mm
Diameter:
25.4mm x 25.4mm
SKU:

304-REC-100-100-120

Table of Contents

Pricing and order information

Laser tube cutting services start from $39 USD per order. Save up to 70% with quantity discounts! We calculate quantity discounts based on several factors including material, density of cut features on each part, and number of duplicate parts. Our app will automatically provide discounted pricing for qualifying parts before checkout.

Materials available for laser tube cutting services

We offer tubes in round, square, and rectanglar shapes in the following materials:

  • 1020 Mild Steel Tube
  • A500 Mild Steel Tube
  • A513 Mild Steel Tube

Laser cut tube shapes and applications

Round tube

  • Roll cages and chassis (motorsports, off-road)
  • Handrails and guardrails
  • Structural supports and braces
  • Bicycle frames and furniture
  • Exhaust tubing and fluid lines

Square tube

  • Frames for trailers, carts, and machinery
  • Table bases and industrial furniture
  • Fencing and gates
  • Signposts and enclosures
  • Welded steel structures

Rectangular tube

  • Frame rails and subframes (automotive, trailers)
  • Support beams and structural columns
  • Racking systems and shelving
  • Fabricated enclosures and frames
  • Table legs and benches

Best file formats for metal tube cutting online

Files accepted for tube parts by our instant pricing system:

AutoCAD.step, .stp
Inventor.step, .stp
Fusion.step, .stp
SolidWorks.step, .stp

For tube laser cutting, we accept STEP and STP format 3D files. We recommend downloading one of our DXF or STEP files listed above to start your project using the correct profile for the tube material needed.

If there’s trouble uploading your finished file to our pricing system, please ensure your design meets all requirements listed in these guidelines.

File set up and design considerations

One tube part per file – no assemblies!

Files that include more than one model will not be processed correctly. Include only one part per file for accurate pricing and production.

Model standard 2D, full depth cut features

We offer standard laser tube cutting services, so all cuts must be modeled as full-depth features perpendicular to the material surface. We don’t provide multiaxis tube cutting or blind features.

Additionally, post processing is not available for tube stock at this time. Please do not model taps, countersinks, or other dimensional features we won’t be able to produce.

Set up tube parts in 1:1 scale, using inch or millimeter units

Design your parts exactly as you want them cut in 1:1 scale, using the same wall thickness as the tube stock you plan to order.

Our system recognizes inch and millimeter units only. Use either inches or millimeters when designing to ensure your overall part size is interpreted correctly.

Tube external corner radii

For steel and non-extruded tube materials, model the external corner radius of square and rectangular tube parts with a corner radius of 3x the tube wall thickness.

Please note, the actual external corner radius for square and rectangular tube stock will range between 1.5-3x the tube wall thickness.

Download our tube profiles

Each tube material option has CAD files available to download with the tube profile found at the beginning of this page. We recommend starting your designs with our profiles to save time and get the most accurate parts possible.

Adjacent cutouts should be bridged if needed

We’re unable to include drop-throughs or scrap pieces that are cut out of your tube design, so think of your cut features like stencils and include bridging if needed. Bridging or webbing helps retain desired features in your final design.

Reference hole, cutout, and bridging/webbing specifications

Ensure all cut geometry meets the minimum requirements for the tube material you plan to order. All design specifications including minimum hole/cutout and minimum bridging/webbing size are listed in our material specs above.

Tube model axis alignment

When modeling your tube design, it’s best practice to align your part to the Y axis of your CAD software’s coordinate system.

Weld compensation (normalization)

At SendCutSend, we automatically normalize joints on all tube models so your parts will match up cleanly when it’s time to fasten or weld.

Non-normalized weld joint
Normalized weld joint

And don’t worry about kerf compensation – we’ll handle that automatically, too!

No etching or engraving

We do not offer cosmetic etching or engraving for any material at this time. Although we offer faint single line etching for part markings on select sheet metal materials, this special service is not available for tube stock.

What to expect from finished parts

  • Overall tolerance on cut features will be +/- 0.005”

  • Tolerance between cut features and non-cut features will be +/- 0.015”

  • There will be a slight conical taper present in the cut due to how tube is laser cut; the taper will be more noticeable in thicker materials and smaller diameter tubes

  • There will be dross and burr present inside tube parts from the cutting process

  • Non-extruded square and rectangular tube will have a weld seam on the inside of the tube

  • We do not perform post processing for tube parts at this time, so any desired dross, burr, or seam removal will need to be performed when parts get to you

  • If you design tabs and slots in your tube parts, the weld seam may land on a tab; this means you may need to file off the weld seam to achieve the desired fitment

  • We’re unable to guarantee part performance for end use; if your tube parts will serve a structural and/or load bearing function, observe best practices and standards for welding, assembly, and safety

Pre-flight checklist

Start your first SendCutSend project today!

Upload your CAD design, or try one of our customizable part templates to get instant pricing on your custom laser cut parts. All delivered to your door in a matter of days.

6061 T6 Aluminum Square Tube

1" x 1" WxH | 0.062" Thick

6061 T6 Aluminum Square Tube

3" x 3" WxH | 0.125" Thick

6061 T6 Aluminum Rectangle Tube

2" x 1" WxH | 0.062" Thick

6061 T6 Aluminum Rectangle Tube

3" x 1" WxH | 0.125" Thick

A513 T5 1020 Mild Steel Round Tube

1.75" Diameter | .095" Thick

A513 T5 1020 Mild Steel Round Tube

1.75" Diameter | .120" Thick

A513 Mild Steel Square Tube

2" x 2" WxH | .120" Thick

A500 Mild Steel Square Tube

2" x 2" WxH | .188" Thick

A500 Mild Steel Rectangle Tube

4" x 2" WxH | 1.88" Thick

304 Stainless Steel Square Tube

1" x 1" WxH | 0.120" Thick

6061 T6 Aluminum Square Tube

25.4 x 25.4mm WxH | 1.58mm Thick

6061 T6 Aluminum Square Tube

76.2 x 76.2mm WxH | 3.2mm Thick

6061 T6 Aluminum Rectangle Tube

50.8 x 25.4mm WxH | 1.58mm Thick

6061 T6 Aluminum Rectangle Tube

76.2 x 25.4mm WxH | 3.2mm Thick

A513 T5 1020 Mild Steel Round Tube

1.75" Diameter | .095" Thick

A513 T5 1020 Mild Steel Round Tube

44.45mm Diameter | 2.41mm Thick

A513 Mild Steel Square Tube

50.8 x 50.8mm WxH | 30.48mm Thick

A500 Mild Steel Square Tube

50.8 x 50.8mm WxH | 4.78mm Thick

A500 Mild Steel Rectangle Tube

101.6 x 50.8mm WxH | 4.78mm" Thick

304 Stainless Steel Square Tube

1" x 1" WxH | 0.120" Thick

4130 Chromoly Square Tube

1.0" x 1.0" | .065" Thick
Photo here with specs called out

4130 Chromoly Square Tube

.75" x .75" | .049" Thick
Photo here with specs called out