Submitting a poorly prepared file to a laser cutting vendor can cost you time, money, and material waste. The difference between a smooth production run and frustrating delays often comes down to what you send in before cutting even starts. This checklist walks you through exactly what vendors need—and what you need to verify—so your design moves from concept to finished product without hiccups.
Know Your File Format Requirements
Most laser cutting vendors accept vector files: AI, EPS, PDF, or DXF are industry standards. Raster files like JPG or PNG won't work because the laser needs precise paths to follow, not pixel data. Before you finalize anything, confirm with your vendor which formats they prefer—some shops have strong opinions on PDF vs. AI, especially for complex designs.
Save your file in the format they request, then open it in the same software they use to verify nothing broke during conversion. A simple test: can you see your design clearly in their native software? If lines look fuzzy, colors shift, or fonts convert to outlines unexpectedly, you've caught a problem early.
Convert All Fonts to Outlines or Curves
Text in your design needs to be converted to curves or outlines before submitting. If you don't, the vendor's software may not have your font installed, and the text will either disappear or substitute with a default font—leaving you with engraved gibberish or a blank space. Most design software (Illustrator, Corel Draw, Inkscape) has a "convert to curves" or "outline text" function; use it.
One exception: if your vendor explicitly says they'll handle font conversion, confirm they have the specific fonts you used. When in doubt, convert anyway—it takes 30 seconds and eliminates risk.
Set Your Line Weights and Colors Correctly
Laser cutting vendors use line weights and colors as instructions:
- Black or red lines (1-point weight, no fill) typically mean "cut this"
- Blue lines often signal "score" or "etch" depending on your vendor's setup
- Gray or light color lines are sometimes ignored or treated as guides
Confirm the exact color scheme your vendor uses. A thin 0.5-point line weight is safest for cutting; thicker lines can cause inconsistencies. Never use gradients or semi-transparent colors—the laser either cuts or it doesn't. Replace any gradients with solid colors that match your intent.
Verify Dimensions and Scale
Your file's dimensions must match the physical size you want. If your design is 6" × 4", the artboard or canvas in your design software should be exactly 6" × 4"—not 600 × 400 pixels (which scales differently depending on DPI).
Check your unit system too: if you're working in inches but your vendor quotes in millimeters, a miscalculation here turns a 2" piece into a 50mm piece. Most vendors will catch this and ask, but verifying yourself saves back-and-forth email delays.
Account for Kerf and Material Margins
Kerf is the material thickness the laser removes during cutting—typically 0.01" to 0.03" depending on material and laser power. If you're cutting interlocking pieces (like a puzzle), you need to account for kerf so parts fit properly. Most vendors handle kerf calculations automatically, but mention it in your notes if precision fit is critical.
Add a 0.25" margin around your design away from the material edge. Lasers can't cut cleanly at the very edge of stock material, and edge charring is harder to control there.
Double-Check Your Design for Common Mistakes
Before hitting send:
- Look for stray lines or nodes (small marks you didn't intend)
- Verify no text is still text—all should be outlined
- Ensure no strokes are set to "none" (you'll lose cutting paths)
- Check that your artboard doesn't contain extra elements outside your intended design area
- Test-open the file one final time in a viewer like Adobe Reader to see exactly what the vendor will see
Communicate Material and Quantity Clearly
Don't assume the vendor knows what you want cut. State it explicitly: "Cut 50 pieces in 1/4\" acrylic" beats "cut some stuff." Include material color, thickness, finish preferences, and whether you want edge polishing post-cut (which adds $15–$40 per order depending on material).
Frequently Asked Questions
Q: What happens if I submit a Photoshop file or rasterized PDF? The vendor will likely reject it or charge a redesign fee (typically $25–$75) to vectorize it manually. Always start with vector software or hire someone to convert your design before submitting.
Q: How long does file approval usually take? Most vendors review files within 24 hours. If your file is clean and properly formatted, approval is instant; messy files trigger back-and-forth corrections that stretch timelines to 2–3 days.
Q: Can I use Canva or online design tools to create files for laser cutting? Some newer tools export as proper vectors, but most are unreliable for precision cutting. Stick with industry standards like Adobe Illustrator, Corel Draw, or free alternatives like Inkscape if you want to avoid vendor rejections and extra fees.
When you're ready to submit, platforms like Mercoly let you compare laser cutting providers, review their file requirements side-by-side, and submit to multiple vendors simultaneously—ensuring your perfectly formatted file reaches vendors who actually want it.