How to Prepare CAD Models for Laser Cutting – A DesignWithAjay Tutorial

At Ajay Industries, laser cutting is more than just a fabrication method—it’s a precision-driven process that starts with smart CAD modeling. Whether you’re designing shredder blade profiles, sheet metal housings, or custom fixtures, preparing your CAD files correctly ensures clean cuts, minimal rework, and seamless integration with CAM software.

This tutorial outlines our proven workflow for preparing laser-ready CAD models using SolidWorks and AutoCAD, optimized for industrial-grade results.

Why Laser-Ready CAD Matters

Laser cutters require clean, 2D vector paths with consistent line weights and closed contours. Poorly prepared files can lead to:

• Incomplete cuts or skipped features
• Burn marks from overlapping geometry
• CAM errors during toolpath generation
• Material waste and machine downtime

DesignWithAjay’s CAD-to-Laser Workflow

1. Model in 2D or Flatten 3D Geometry

• Use SolidWorks Sheet Metal tools or AutoCAD for 2D profiles
• For 3D parts, create a flat pattern or use Convert Entities to extract outlines
• Ensure all sketches are fully defined and planar

Ajay Tip: Use configurations to isolate laser-cut profiles from full assemblies.

2. Clean Up Geometry

• Remove hidden lines, construction geometry, and overlapping entities
• Ensure all contours are closed loops—no gaps or open ends
• Use Overkill in AutoCAD to delete duplicates

Ajay Tip: Zoom in and inspect corners and fillets for micro-gaps that can confuse CAM software.

3. Standardize Line Types and Layers

• Cutting lines: Continuous, typically on “CUT” layer
• Engraving lines: Dashed or colored differently, on “ENGRAVE” layer
• Use consistent line weights (e.g., 0.00 mm for vector paths)

Ajay Tip: Create a custom layer template for laser projects to avoid manual setup.

4. Assign Material and Thickness

• Include material callouts in the title block or layer name
• Specify thickness (e.g., MS 3mm, SS304 1.5mm) for CAM compatibility
• Match material specs with your BOM and procurement sheet

Ajay Tip: Use global variables in SolidWorks to control thickness across multiple parts.

5. Export in Compatible Format

• Preferred formats: DXF, DWG, or SVG (for vector-based cutters)
• Use File > Save As > DXF in SolidWorks and select “Flat Pattern”
• In AutoCAD, use EXPORT or SAVEAS with version compatibility (e.g., AutoCAD 2013)

Ajay Tip: Always preview the exported file in a viewer before sending to CAM.

Real-World Example: Shredder Blade Profile

CAD Model: Hooked blade with bolt holes and relief cuts Process:

• Flattened using Sheet Metal tools
• Cleaned geometry with closed contours
• Exported as DXF with “CUT” and “ENGRAVE” layers Outcome: Zero CAM errors, perfect edge quality, and reduced setup time

What You Get with Every DesignWithAjay Laser-Ready File

• DXF/DWG exports with clean geometry
• Layered line types for cutting and engraving
• BOM with material and thickness specs
• Flat pattern drawings with dimensions
• Revision history and fabrication notes