Tolerance & Design Guide
Achievable tolerances, minimum feature sizes, and design rules for laser cutting, CNC machining, sheet metal bending, and 3D printing. Design better parts from the start.
Laser Cutting
Fibre laser cutting of flat sheet metal. Best for 2D profiles, holes, slots, and cutouts.
Min Feature Size
~1mm (depends on thickness)
Max Part Size
3000 × 1500mm
Surface Finish
Ra 3.2–6.3 μm on cut edge. Top/bottom surfaces unchanged.
Materials
6 options
Achievable Tolerances
| Feature | Typical | Best Achievable | Notes |
|---|---|---|---|
| Cut profile position | ±0.2mm | ±0.1mm | Depends on material thickness — thinner = tighter |
| Hole diameter | ±0.15mm | ±0.1mm | Holes < material thickness may have taper |
| Hole position | ±0.2mm | ±0.1mm | Relative to other features on same part |
| Part-to-part consistency | ±0.1mm | ±0.05mm | Parts on same sheet are very consistent |
| Kerf width | 0.15–0.3mm | Varies | Thinner material = narrower kerf. Compensated in software. |
| Edge squareness | < 1° | < 0.5° | Mild taper on thick cuts (>10mm) |
Design Rules
Minimum hole diameter = material thickness
A 3mm thick sheet needs minimum 3mm diameter holes. Smaller holes are possible but may have quality issues (taper, dross).
Minimum slot width = material thickness
Narrow slots in thick material risk incomplete cutting and dross buildup.
Minimum web between features = material thickness
The wall between two holes or a hole and the edge should be at least as thick as the material. Thinner webs may warp from heat.
Corner radius ≥ 0.5mm (thin) or 1mm (thick)
Sharp internal corners cause the laser to slow down, increasing heat input. Add small radii for cleaner cuts and better fatigue life.
Edge distance for bends ≥ 2× thickness + bend radius
If the part will be bent, keep holes and cutouts away from bend lines to prevent distortion.
Minimum part size: 10mm × 10mm
Very small parts are difficult to handle and may fall through the laser bed slats. Tab with microjoints for parts under 20mm.
Maximum sheet size: 3000mm × 1500mm
Our laser bed accepts full sheets. Parts larger than this need to be split and welded.
Text/engraving: minimum 2mm character height
Smaller text may be illegible or inconsistent depending on font. Use simple sans-serif fonts for best results.
Available Materials
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Frequently Asked Questions
What tolerance can laser cutting achieve?
What is the minimum hole size for laser cutting?
What is the minimum bend radius for sheet metal?
How accurate is CNC turning?
How do I design parts for manufacturing (DFM)?
Related Resources
- Laser Cutting Design Guide — DFM tips, minimum feature sizes, and design rules for laser-cut parts
- How to Design for Sheet Metal — bend radii, hole spacing, flange lengths, and common DFM mistakes
- How to Prepare DXF Files for Laser Cutting — file preparation guide with feature size tables by thickness
- Common Fiber Laser Cutting Problems — troubleshooting edge quality, burrs, and parameter issues
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