How to prepare a file for laser cutting, scoring and engraving and export it to DXF or SVG

Introduction

Most laser cutting and engraving problems do not come from the machine: they come from the file. Duplicate lines, misinterpreted colours, unconverted text, incorrect scales or thick outlines that the software “reads” as two lines. If you prepare the file properly, the job comes out clean, fast and repeatable.

At Vanco Studio we work with CO₂ laser cutting and engraving in Girona, and an important part of the result depends on the vector being properly constructed before pressing “Start”.

Cutting, scoring and engraving: what each means in the file

In laser work, we usually separate three work “intentions”. It is not just a matter of names: it changes how the line is interpreted and what we expect from the finish.

Cutting: the laser passes through the material. In the file, this is a vector line executed as an outline. If there is a double line or an outline with thickness, the laser may pass twice and burn the material or alter the dimensions.

Score (marking / creasing): this is a light pass used to mark, guide a fold or create a reference line. We are not looking for depth; we want a fine, continuous mark. On materials such as cardboard or thin wood, a poorly prepared score can become a “wide engraving” if the line is not correct.

Engraving: this can be vector-based (lines) or fill-based (areas). With CO₂, area engraving usually translates into many scanning passes. That is why it is advisable to simplify and close the shapes properly.

If you want a more criteria-based explanation (when each process is appropriate), see this guide: laser cutting vs laser engraving: differences and when to use each one.

Workshop rules so the laser interprets the design as you expect

This is what we repeat most often when preparing customer files in graphic design for manufacturing: the file must be “unambiguous”.

• Everything as true vectors: no raster images “matched” with hand-drawn lines. If there is a logo or typography, it must be vectorised or created as curves.
• No thick strokes for cutting: the cut must be a zero-width line (hairline) or the standard used by the software. A thick stroke can become two outlines.
• Remove duplicates: duplicate overlapping lines make the laser pass twice over the same place. The typical result: more burning and inconsistent dimensions.
• Closed shapes for fill engraving: if you want to engrave an area (for example, a black fill), make sure the shapes are closed and have no micro-gaps.
• Text converted to curves: if we do not convert it, we depend on the font being installed on the computer preparing the machine. Converting to curves prevents typeface changes or kerning shifts.
• Work at 1:1 scale: not “by eye”. Define the final size from the start and do not leave it until the last minute.

How to separate layers: a practical way to “tell” the laser what each element is

The most common way to organise a laser file is by layers or colours: one layer/colour for cutting, another for scoring and another for engraving. This allows the software to assign different power/speed settings to each group.

A method that works well in almost any workflow is:

Cutting: a single layer of outlines (no duplicates, lines only).
Score: a layer of marking lines (no duplicates, no thickness).
Engraving: a layer of areas (no duplicates, with fill).

The idea is that if you hide one layer, the rest should still make sense. This prevents “mixed” files where it is unclear what should be cut and what should be marked.

Exporting to SVG and DXF: what to check before sending the file

SVG and DXF are two common manufacturing formats, but they do not behave in the same way. SVG usually preserves colours/layers better and is very practical in laser-cutting workflows. DXF is an industrial standard, but it may lose colour information or interpret splines and text differently depending on the software.

Before exporting (and before sending it), review this checklist:

• Units: confirm whether the document is in mm (the most common) and that exporting/importing does not change it to inches.
• Curves and nodes: simplify unnecessary nodes; too many nodes slow the process and can cause vibration on curves.
• Curve compatibility: if you export DXF, it is advisable to convert effects/complex curves into clean paths (some DXF files “break” certain splines).
• No masks or effects: shadows, transparencies and visual effects are not manufacturing geometry. Convert everything into real geometry.
• Import test: open the exported file in another program or re-import it to check scale, layers and lines.

A practical tip: if your design comes from an image or an external resource, there is nothing wrong with starting from an existing base (a downloaded vector, the customer’s logo, a pattern). What matters is normalising it for manufacturing: clean up nodes, close shapes, remove duplicates and leave it machine-ready. This saves time and reduces errors without sacrificing quality.

The material you are going to use also affects the file

The same design may work perfectly in MDF and fail in acrylic if it has details that are too fine or if the engraving covers too much surface area. Before finalising the file, it is worth considering the material and the desired finish.

If you are choosing a material, this guide will help you make decisions: which materials can be laser cut or engraved.

Designing for laser is not about “drawing something pretty”: it is about drawing so the machine can interpret it without ambiguity. If you separate cutting/scoring/engraving correctly, remove duplicates, work at actual scale and export with a final check, you eliminate 90% of the typical problems.

If you want, we can review your file before manufacturing or prepare it from scratch so the result comes out right the first time, with the appropriate material and finish.