Master the complete workflow from CAD file preparation to customer-ready quotes. Includes file validation, material selection, cost calculation, and quality control best practices.

1) CAD File Preparation & Validation

Proper file preparation is critical for accurate quotes and successful production.

File Format Requirements

DXF/DWG: Most common, ensure version R12-R2018 for compatibility
SVG: Good for simple shapes, verify scale on import
AI/EPS: Convert text to paths, flatten layers

Unit verification: Always use millimeters (mm) as standard. Check drawing units in CAD properties before export.
Layer management: Place cutting paths on separate layers from dimensions/notes. Delete hidden or reference layers.
Path validation: Ensure all paths are closed polylines. Use "Join" command to connect broken segments.
Remove duplicates: Delete overlapping lines that cause double-cutting and wasted time.
Measure total length: Use CAD measurement tools to sum outer contour + all internal holes. Record this value.
Count pierces: Each closed contour requires one pierce. Include outer edge + all holes.

2) Material Selection & Specifications

Material choice directly impacts cutting speed, quality, and total cost.

Material	Common Grades	Assist Gas	Edge Quality
Mild Steel	A36, 1018, 1020	O₂ (fast) or N₂ (clean)	Oxide layer with O₂
Stainless Steel	304, 316, 430	N₂ (required)	Bright, clean edge
Aluminum	5052, 6061	N₂ or Air	Dross on bottom edge
Galvanized	G90, G60	N₂ (avoid fumes)	Zinc coating affects

Thickness tolerance: Standard is ±0.1mm for <6mm, ±0.2mm for 6-12mm. Verify with supplier.
Surface finish: Hot-rolled (HR) has scale, cold-rolled (CR) is smooth. Affects edge quality.
Sheet size: Standard 4'×8' (1220×2440mm) or 5'×10' (1525×3050mm). Confirm availability.

3) Cost Calculation & Parameters

Accurate cost estimation requires understanding all cost components.

Cost Breakdown Formula

Material Cost = Sheet price × (Part area + kerf loss + scrap) ÷ Sheet area

Cutting Time = (Length ÷ Speed) + (Pierce count × Pierce time) + Setup time

Labor Cost = Cutting time × Operator hourly rate

Machine Cost = Cutting time × (Power cost + Gas cost + Depreciation + Maintenance)

Total Cost = Material + Labor + Machine + Overhead

Cutting speed: Varies by material/thickness. 1mm mild steel: 10-15 m/min; 10mm: 0.8-1.2 m/min.
Pierce time: 0.5-2 seconds per pierce depending on thickness and gas type.
Setup time: Include 5-15 minutes for sheet loading, program verification, first-piece inspection.
Kerf allowance: Typical 0.1-0.3mm per side. Use Kerf Reference calculator for exact values.
Material utilization: Target 70-85% for standard jobs, 85-92% for optimized nesting.
Batch considerations: Setup cost amortized across quantity. Offer volume discounts for 50+ pieces.

4) Quality Control & Tolerances

Define quality requirements upfront to avoid rework and disputes.

Standard Tolerances

Linear dimensions: ±0.1mm for features <100mm, ±0.2mm for 100-500mm
Hole diameter: +0.1/-0mm (slightly oversized due to kerf)
Perpendicularity: ±1° typical, ±0.5° for precision work
Edge roughness: Ra 6.3-12.5 μm typical for laser cutting

Dimensional verification: Measure critical features on first piece before running full batch.
Edge quality inspection: Check for dross (bottom edge buildup), burrs, and heat-affected zone (HAZ).
Flatness check: Thermal distortion can occur on thin sheets (<1mm) with long cuts.
Corner sharpness: Inside corners have radius equal to kerf width (~0.1-0.2mm).
Documentation: Include tolerance callouts on quote. Default to ISO 2768-m if not specified.

5) Quote Generation & Customer Communication

Professional quotes build trust and streamline the approval process.

Cost transparency: Break down material, labor, machine time, and overhead separately. Builds credibility.
Pricing strategy: Use 25-35% markup for standard work, 40-50% for rush jobs or complex parts.
Volume tiers: Offer 3-4 quantity breaks (e.g., 1-10, 11-50, 51-100, 100+) with 5-15% discounts.
Lead time: Standard 3-5 business days. Add 20-30% cost for 24-48 hour rush service.
Terms & conditions: Include payment terms (Net 30), material substitution policy, and tolerance standards.
Validity period: Quote valid for 30 days. Material prices fluctuate, especially for stainless and aluminum.
Revision tracking: Use version numbers (v1.0, v1.1) and date stamps for quote history.

Quote Checklist

✓ Part description and quantity
✓ Material specification (grade, thickness, finish)
✓ Itemized cost breakdown
✓ Lead time and delivery method
✓ Payment terms and validity period
✓ Tolerance and quality standards
✓ Company contact info and quote number

6) Common Issues & Solutions

Anticipate and resolve common problems before they impact production.

❌ DXF Import Fails or Displays Incorrectly

Cause: Version incompatibility, wrong units, or complex entities (splines, 3D objects).

Solution: Export as DXF R12 (universal), convert splines to polylines, flatten to 2D, verify units.

❌ Parts Don't Fit Together (Tolerance Issues)

Cause: Kerf not accounted for, material thickness variation, thermal distortion.

Solution: Apply kerf compensation (+0.1mm per side for slots), test-fit first piece, use fixturing for thin parts.

❌ Poor Edge Quality (Dross, Burrs, Discoloration)

Cause: Wrong gas type, incorrect pressure, worn nozzle, slow cutting speed.

Solution: Use N₂ for clean edges, check nozzle condition, optimize speed/power parameters, add deburring step to quote.

❌ Nesting Efficiency Too Low (<70%)

Cause: Poor part arrangement, excessive spacing, no rotation optimization.

Solution: Use nesting software, allow 90°/180° rotation, reduce spacing to 3-5mm, combine similar jobs.

❌ Quote Rejected as "Too Expensive"

Cause: Customer comparing to high-volume pricing, unrealistic expectations, competitor underbidding.

Solution: Explain cost breakdown, offer volume discounts, suggest design changes to reduce cost (fewer pierces, simpler shapes).

7) Real-World Case Studies

Learn from actual projects across different complexity levels.

📊 Case 1: Simple Bracket (Low Complexity)

Part: L-shaped mounting bracket

Material: 3mm mild steel (A36)

Quantity: 50 pieces

Cutting length: 280mm per part

Pierces: 3 (outer + 2 holes)

Cutting time: 1.2 min/part

Material cost: $1.80/part

Labor + machine: $2.40/part

Total cost: $4.20/part

Quote price: $5.60/part (33% margin)

Key insight: Simple geometry allows 82% nesting efficiency. Setup time amortized across 50 pieces reduces per-part cost.

📊 Case 2: Decorative Panel (Medium Complexity)

Part: Architectural screen panel

Material: 2mm stainless 304

Quantity: 12 pieces

Cutting length: 4,800mm per part

Pierces: 48 (complex pattern)

Cutting time: 18 min/part

Material cost: $28.50/part

Labor + machine: $36.00/part

Total cost: $64.50/part

Quote price: $95.00/part (47% margin)

Key insight: High pierce count increases time significantly. N₂ gas required for clean stainless edges adds $8/part. Premium margin justified by complexity.

📊 Case 3: Precision Enclosure (High Complexity)

Part: Electronics enclosure with tight tolerances

Material: 1.5mm aluminum 5052

Quantity: 5 pieces (prototype)

Cutting length: 1,200mm per part

Pierces: 24 (mounting holes + cutouts)

Cutting time: 8 min/part

Material cost: $12.00/part

Labor + machine: $16.00/part

Total cost: $28.00/part

Quote price: $45.00/part (61% margin)

Key insight: Low quantity means setup cost ($75) heavily impacts per-part price. Tight tolerances (±0.05mm) require first-piece inspection and slower speeds. High margin accounts for risk and low volume.

Professional Calculators

Core Calculators

Cost Center

Analysis

From CAD to Quote: Complete laser cutting workflow in 20 minutes