Flat-sheet design review
Laser Cutting Design Limits
Check holes, slots, bridges, and edge distance as three separate decisions: can the supplier cut the feature, will it meet the drawing, and will the part meet its design load? Passing one does not pass the others.
Content reviewed 2026-11-02. Verify the applicability of each source before using a value in a quote.
Input to record
Use the exact grade and stock thickness, drawing revision, minimum feature dimensions, supplier-specific cutting limits, and any secondary operations.
Output to carry forward
A pass, revise, or engineering-review decision for each feature. Keep the supplier requirement separate from the finished drawing and strength requirements.
Clearance example
For an illustrative 6 mm diameter hole whose center is 10 mm from a straight outer edge, the remaining web is 10 − 6 ÷ 2 = 7 mm. Compare that 7 mm clear distance with the chosen supplier’s hole-to-edge requirement. This arithmetic does not establish that 7 mm is acceptable for a particular material, load, or process.
Release checks
- Choose the actual material and stock thickness in the supplier’s catalog. Do not apply another thickness’s minimums.
- Check negative geometry, retained positive bridges, and clear edge distance independently. A center-to-center dimension can hide an inadequate web.
- Check tapping, countersinking, hardware, and bending requirements separately; the plain cutting minimum may not cover these operations.
- Request a representative first article when dimensions or edge quality are critical. Record the measured result against the drawing.
- Use the drawing’s engineering approval for strength. A cut coupon is not a strength certification.
Sources and scope
Content reviewed 2026-11-02. A documentation reference supports the stated method or data only; it does not approve settings on another machine.
- SendCutSend — 10 Common Reasons Your Design is Failing Preflight
Supplier-specific DFM guidance. Defines minimum hole, bridge, and hole-to-edge geometry by the selected material and stock thickness; it is not a universal machine limit.
Showing 5 of 5 rows
| Feature | How to measure | Can cut | Dimensional / strength review | Source | Applicability / confidence | Reviewed |
|---|---|---|---|---|---|---|
| Hole / internal cutout | Measure the smallest negative opening, not its bounding box. Compare it with the selected stock-thickness minimum. | Supplier minimum hole size is a cut-capability screen. | Verify finished diameter/position to drawing; tapped or countersunk holes need their own operation rules. | SendCutSend: Geometry Too Small | Verified supplier procedure; numeric limit must match selected stock | 2026-11-02 |
| Narrow slot | Check the minimum slot width and the long unsupported strips on each side. Do not infer width acceptance from slot length. | Negative geometry must satisfy the cutting supplier’s material-specific minimum. | Inspect width, taper, and flatness; a cuttable slot may still distort or miss drawing dimensions. | SendCutSend: Geometry Too Small; Design Density & Fragility | Verified qualitative procedure; job-specific release | 2026-11-02 |
| Bridge / retained island | Connect every interior shape intended to remain in the part. Measure the narrowest positive section. | Supplier minimum bridge width addresses whether material can be retained during cutting. | Bridge strength, fatigue, and handling capacity require the design load case; cut capability does not certify strength. | SendCutSend: Loose Interior Shapes | Verified supplier procedure; strength requires engineering review | 2026-11-02 |
| Hole to edge / hole to hole | Measure clear material between cut edges, not center-to-center distance. For a circular hole near an outer edge: clear distance = center-to-edge − hole radius. | Use the supplier’s hole-to-edge value for the chosen material/thickness. | Secondary hole operations and structural edge-distance requirements are separate checks. | SendCutSend: Min Hole to Edge Size | Verified geometry definition; no universal clearance asserted | 2026-11-02 |
| Dense or fragile profile | Review long strips, removed areas, residual stress, and loose pieces that may tip up during cutting. | Supplier review may request bridges or a less fragile profile even if individual features meet minima. | Confirm flatness, deburring access, packaging, and end-use stiffness independently. | SendCutSend: Design Density & Fragility; Shipping & Handling | Verified qualitative procedure; representative test recommended | 2026-11-02 |
Reference workflow
- Match the job, material, machine head, and quality requirement to a row.
- Confirm the source, review date, and confidence before copying the value into a quote worksheet.
- Use a measured result or current OEM record when the row is marked as required or unverified.