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What Is Laser Cutting? A Complete Guide to Process, Materials, + Design

  • Mar 31
  • 2 min read

Laser cutting is one of the most efficient and precise methods for cutting sheet metal in modern manufacturing. Whether you're designing custom parts or scaling production, understanding how laser cutting works, and how it compares to other methods, can help you make better

decisions for your project.



A laser cutting machine emits bright sparks while cutting metallic sheet. The industrial setting is lit with cool blue tones.

What Is Laser Cutting and How Does It Work?

Laser cutting is a fabrication process that uses a high-powered, focused laser beam to cut through metal with extreme precision.

At Laserfly Cutting House, we use fiber laser cutting technology, which is known for speed, accuracy, and clean edge quality.


How the process works:

  • A digital file (DXF, DWG, or STEP) is uploaded into the machine

  • The laser follows the programmed path of your design

  • A high-intensity beam melts or vaporizes the material

  • Assist gas (like nitrogen) removes molten material and prevents oxidation

  • Finished parts are cut cleanly and ready for the next step


Key benefits of laser cutting: + High precision and tight tolerances + Clean, smooth edges with minimal finishing required + Fast processing speeds for production runs + Minimal material distortion due to low heat impact


Close-up of a metal sheet with intricate cutout patterns on a black industrial press table, depicting precise engineering or manufacturing.

How to Design Parts for Laser Cutting

Designing with laser cutting in mind can save time, reduce costs, and improve part quality.


Best practices for laser cut design:

  • Use vector-based files (DXF or DWG preferred)

  • Keep minimum feature sizes at least equal to material thickness

  • Avoid overly tight internal corners (small radii improve accuracy)

  • Account for kerf width (~.005”) when designing tight tolerances

  • Maintain proper spacing between parts to allow for clean cuts

  • Use etching for part numbers or bend lines when needed


Pro tip: Simple, clean designs not only cut faster, they also reduce material waste and overall cost.


Abstract pattern of overlapping gray triangular cut-outs. Geometric design with sharp angles and shadows creating a textured effect.

What Materials Can Be Laser Cut?

Fiber laser cutting is highly versatile and can process a wide range of metals.


Common materials we cut:

  • Steel

  • Stainless steel

  • Aluminum

  • Copper

  • Brass

  • Other non-ferrous metals


Unlike traditional laser systems, fiber lasers are capable of cutting highly reflective materials like copper and brass with ease.


Material capabilities at Laserfly:

  • Maximum sheet size: 60” x 120”

  • Maximum thickness: 1/4” (.25”)

  • Suitable for both prototype and high-volume production


If you have a unique material requirement, our team can test it to ensure compatibility.



Stylized fly illustration in a hexagonal frame with a dark honeycomb pattern. The fly is white with green eyes, conveying a sleek design.

Start Your Next Laser Cutting Project

Ready to bring your design to life?


Get started today: + Upload your DXF, DWG, or STEP file + Request a custom quote + Talk with our team about your project specs

Have questions about materials or design? We’re happy to help guide you through the process.

Let’s get your parts into production.



 
 
 

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