Tube Laser Design Guide
Designing for laser tube cutting isn’t just about making the part cuttable — it’s about unlocking efficiency across your entire build process. When implemented correctly, tube laser cutting can dramatically streamline fabrication, reduce welding time, eliminate the need for jigs, and minimize costly rework. This guide is here to show you some of the ways you can streamline your manufacturing process with a tube laser, and best practices when designing for a tube laser.
New Possibilities With A Tube Laser
Tab and Slot Assembly
Design parts that self-locate during welding for faster, more accurate assembly without jigs.
Bend-Ready Cuts
Add bend relief patterns so tubes can be hand-formed into precise angles without custom tooling.
Tube Coping & Saddle Cuts
Make clean, tight-fitting joints between round or square tubes — no grinding or secondary shaping needed.
Laser Engraving
Mark part numbers, orientation lines, or logos directly on the tube — no stickers or Sharpies required.
Design for Manufacturability (DFM) Guidelines
Design
Actual
Keep Cuts Normal to the Tube Surface
The laser will cut perpendicular to the axis of the tube, but you don't necessarily need to design parts that conform to this constraint. We automatically compensate for miters, copes, and other features to ensure that they do not interfere after assembly.
Minimum Feature Size to Material Thickness
Make sure any features like slots or holes are at least as wide as the tube wall thickness. Features smaller than this may not cut cleanly or could deform.
Achievable Laser Cutting Tolerances
Ø - Feature Size Tolerance: ±0.005"
This applies to hole diameters, slot widths, and cutout shapes. Ideal for most mechanical fits.
Y - Position Tolerance: ±0.005"
Accuracy of features along the length of the tube.
X - Position Tolerance: ±0.015"
Edge-referenced features may have slightly more variation due to tube irregularities.