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How to Prepare Files for Laser Cutting and Engraving

Use SVG format for cutting, assign operations by colour layer, apply kerf compensation only when parts must fit together (typically 0.08–0.15 mm per side for a diode laser on wood), and always run engrave before cut. This guide covers the full file-prep workflow for diode lasers — xTool, Sculpfun, Ortur, Atomstack — in LightBurn, LaserGRBL, and xTool Creative Space, including the machine-specific details those other guides skip. — Laser Tinkerer, 2026-07-03

SVG vs DXF — which file format should you use for laser cutting?

For most diode laser users with xTool, Sculpfun, Ortur, or Atomstack machines, SVG is the right choice. LightBurn, xTool Creative Space, and LaserGRBL all import SVG directly and preserve curves as true Bézier paths. DXF — the interchange format from CAD tools — approximates curves as short straight line segments, which can produce noticeably faceted circles on the laser if the export settings are coarse.

DXF makes sense if your design lives in Fusion 360, FreeCAD, or another engineering CAD tool that doesn't export SVG well. LightBurn imports DXF reliably. Just check your export resolution: Fusion 360's DXF spline resolution defaults are usually fine; older or cheaper CAD packages sometimes produce very coarse segment approximations that look angular on the laser.

Layer colour mapping — how to separate cuts, scores, and engraves

Laser software separates operations by layer, and layers are identified by the colour of the path or fill in the design file. There is no industry standard colour scheme — what matters is that each distinct operation lives on its own colour, and you set that colour's parameters (speed, power, mode) correctly in LightBurn or Creative Space.

A common hobbyist convention that works well:

• Red (#FF0000): outer cut lines — set to Line mode, cut power/speed
• Blue (#0000FF): score or shallow vector engrave lines — Line mode at lower power
• Black fill (#000000): raster engrave areas — Fill mode
• Green (#00FF00): inner holes or cut-outs — Line mode, same as cuts

In Inkscape, assign these stroke colours to paths. Set stroke width to 0.01 mm or the thinnest option — a thick stroke width in the SVG sometimes imports as a coloured band rather than a hairline in LightBurn.

Layer operation order (always do this)

In LightBurn's Cuts / Layers panel, drag layers so they execute in this order:

1. Raster engrave fills (bottom of list = first to run)
2. Score or shallow vector lines
3. Inner cut-outs (holes)
4. Outer cut paths (top of list = last to run)

Running the outer cut last prevents your cut pieces from falling or shifting before the surface engraving is complete. An off-register engrave on a shifted piece is the most common beginner file-prep mistake.

Kerf compensation — when you need it and how to measure it

The laser beam removes a thin strip of material — called the kerf — as it cuts. For diode lasers on wood, the kerf is typically 0.08–0.20 mm depending on wattage, focus accuracy, and material density. For most decorative projects (engraved signs, name plaques, ornaments), the kerf is small enough that you can ignore it entirely.

You need kerf compensation when:

• Two pieces must press-fit together (box tabs, puzzle joints, inlay work)
• You are cutting a hole to exact size for a bolt, magnet, or LED
• Parts will be glued edge-to-edge with tight tolerances

How to measure your kerf

Cut a rectangle with your design software at exactly 50 mm × 50 mm. Measure the actual cut piece with calipers. If it measures 49.86 mm, your kerf is 0.14 mm. Apply half the kerf (0.07 mm) as an offset — inward on outer cuts, outward on inner cuts. For the more accurate 10-square method and step-by-step LightBurn instructions, see the full kerf compensation guide.

Kerf reference table by material (diode laser)

Kerf values based on typical 10W–20W diode lasers at correct focus, with air assist. Always measure your own machine — these are starting estimates only. Source: aggregated from community-published caliper measurements; last reviewed 2026-07-03.

Applying kerf compensation in LightBurn

In LightBurn, open the Cuts / Layers panel and double-click the relevant colour layer. In the Cut Settings Editor, enter the kerf offset in the Kerf field. Enter half the total kerf — LightBurn applies it as a one-sided offset. For outside cuts, enter a positive value (path shifts inward, making the piece smaller by kerf/2). For inside cuts (holes), a positive value makes the hole larger by kerf/2. The Preview shows the adjusted path before you run the job.

Step-by-step file preparation workflow

This covers the full flow from design to laser-ready file, using Inkscape as the design tool and LightBurn as the laser control software — the most common setup for diode laser hobbyists.

1. Design in Inkscape (or your preferred tool). Use the Pen/Bezier tool for cut paths. For text you want to cut out, select it and go to Path → Object to Path — this converts live text to outlines so it imports correctly. Check that all paths are closed (no gaps in outlines you want to cut).
2. Assign colours by operation. Select all cut paths → set stroke colour to red, stroke width to 0.01 mm. Select raster engrave fills → set fill colour to black, remove stroke. Select score lines → stroke blue. Keep each operation on its own colour layer.
3. Export as Plain SVG. In Inkscape: File → Save As → Plain SVG (not "Inkscape SVG"). Inkscape SVG embeds Inkscape-specific metadata that occasionally confuses other apps; Plain SVG is cleaner and universally supported.
4. Import into LightBurn. Drag the SVG into LightBurn or use File → Import. Imported colours auto-map to LightBurn's colour layers. Check that each layer's Mode is correct: Line for cut and score paths, Fill for raster engrave areas.
5. Set speed and power for each layer. Use your machine's calibrated settings from the materials database, or use the Test Grid Generator to dial in the specific material. Start conservative and test on scrap.
6. Apply kerf offset if needed. For press-fit or close-tolerance work only: in Cut Settings for the relevant layer, enter half the measured kerf in the Kerf field.
7. Set layer order: fill → score → inner holes → outer cut. Drag the layers in the Cuts panel so engrave fills run first, outer cuts run last.
8. Preview (Alt+P) and Frame before cutting. Always run Preview to confirm the layer order and geometry look right. Then use Frame (or the Framing button on the machine) to trace the boundary on the material without the laser firing — confirm your design is positioned and sized correctly before committing.

Software-specific tips for diode laser users

LightBurn

LightBurn is the most capable software for diode lasers with a GRBL or DSP controller. File prep things specific to LightBurn:

• $32 (laser mode): Make sure your machine's $32 is set to 1 in Edit → Machine Settings → GRBL. Without laser mode, the machine stops at every node to decelerate, leaving burn marks at corners. The LightBurn setup guide covers this.
• Threshold vs Jarvis vs Stucki: For photo engraving, choose dithering in Image Properties (right-click the image in LightBurn). Jarvis and Stucki produce good results for most photos; Threshold is useful for high-contrast logos.
• Tab feature: For cutting out shapes, add tabs (Cut Settings → Add Tabs) to keep pieces from falling as the cut completes. Particularly useful for thin plywood with smaller parts.
• Boolean operations: LightBurn's Boolean Union/Subtract/Intersection (under Tools) work well for combining shapes. If a Boolean fails, check for overlapping nodes at the junction — nudge by 0.01 mm to fix.
• xTool D1 Pro and xTool S1: These use a modified GRBL (LightBurn calls it "GRBL-M3"). If your xTool shows connection issues in LightBurn, select Device type "GRBL-M3" during setup. The machine settings $$ pull correctly via this connection type.

LaserGRBL

LaserGRBL is free and works with any GRBL diode laser, but its file-prep workflow is different from LightBurn:

• LaserGRBL is primarily a raster image engraver. It converts images to G-code by tracing pixel rows. It is not designed for multi-layer vector workflows.
• For cutting shapes in LaserGRBL, import an SVG and use the vector mode — but the layer separation and kerf tools are minimal compared to LightBurn. For anything requiring precision fit, switch to LightBurn for that job.
• A workflow that works: design in Inkscape, export separate files per operation (one SVG for cuts, one PNG for engraving), import each into LaserGRBL separately as G-code, then run them in sequence on the machine.
• LaserGRBL does not support DXF.

xTool Creative Space

xTool Creative Space (xCS) is the free, browser-based software for xTool machines. File prep notes:

• SVG import works well. xCS supports colour layers to separate cut, engrave, and score operations.
• xCS does not have a kerf compensation field. For precision fitting work, export to LightBurn (xTool machines support LightBurn) and use LightBurn's kerf tools.
• Text can be edited live in xCS without converting to paths first — but for SVG export or use in other software, convert text to outlines before exporting.
• The xCS camera alignment feature (if your machine has a camera) shows where your design lands on the material — use it to position without the guesswork of manual framing.

Common file preparation mistakes

Frequently asked questions

Should I use SVG or DXF for laser cutting? SVG is the better choice for most hobbyist diode lasers. LightBurn, xTool Creative Space, and LaserGRBL all import SVG without conversion and preserve curves accurately. DXF is useful when your CAD tool only exports DXF, but can approximate curves as short straight segments depending on the export quality. Start with SVG unless your workflow requires DXF.

What is kerf and do I need to compensate for it? Kerf is the width of material the laser beam removes — typically 0.08–0.20 mm for a diode laser on wood. For decorative engraving and simple cuts, you can ignore it. For parts that must fit together (finger joints, press-fit boxes, inlay work), apply a kerf offset of half the kerf width inward on outside cuts and outward on inside cuts. LightBurn's layer settings include a built-in kerf offset field.

What colour should cut lines be? LightBurn assigns operations by colour layer, not by a fixed convention. A common hobbyist scheme is red for cuts, blue for scores, black fill for raster engraving. What matters is consistency within your own library and that LightBurn's layer operations match the colour's mode. Always use Preview (Alt+P) to confirm the order before cutting.

Why is my text cutting out instead of engraving? Text is imported as paths (outlines), not filled shapes. In LightBurn, make sure the text layer is set to Fill mode, not Line. In LaserGRBL, import the design as a raster image if you want filled engraving. In Inkscape, use Path → Object to Path first, then confirm the paths are closed before exporting.

Can I use a PNG or JPG for laser cutting shapes? Not directly — raster files cannot be used for cutting out shapes. PNG and JPG can only be used for raster engraving, where the laser traces pixel rows across the image. For cutting, you need vector paths (SVG or DXF). If you only have a bitmap logo, use LightBurn's Trace Image (Alt+T) to convert it to vectors first. You can combine both in LightBurn: an SVG for the cut outline and a PNG for the engraved detail inside.

Do Sculpfun and Atomstack machines need any special file settings? No. Sculpfun (S-series, S30) and Atomstack (X-series, A-series) use standard GRBL over USB. They connect to LightBurn as "GRBL" device type and accept standard SVG or DXF files. Confirm $32=1 is set via Edit → Machine Settings in LightBurn for clean engraving (no corner burn marks).

Gear that helps with file preparation

• Digital calipers for measuring kerf A pair of 0.01 mm digital calipers lets you measure your actual cut dimensions precisely — essential for kerf compensation and tight-fitting boxes. Under $20 and used constantly. Search for digital calipers on Amazon ↗
• Honeycomb bed Cutting on a honeycomb keeps the material flat, allows smoke to escape from below, and reduces reflection. Makes a noticeable difference for clean cuts and also simplifies framing and material positioning. Search for laser honeycomb beds on Amazon ↗
• OD7+ 450nm laser safety glasses Required during any laser session. OD7 rating blocks the diode's 445–450 nm wavelength to safe levels. Cheap clip-ons are not adequate — use rated eyewear. Search for OD7 laser safety glasses on Amazon ↗

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