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Fabrication Notes
CutCase produces SVG geometry for fabrication, but physical fit must still be validated on the actual machine and material.
Laser-cut parts are affected by:
- actual material thickness
- material density
- laser power
- cutting speed
- focus height
- lens condition
- air assist
- bed flatness
- humidity
- material batch
Two sheets sold as the same nominal thickness can fit differently.
Use calipers. Measure in several locations and use a realistic average.
Examples:
| Nominal | Possible measured values |
|---|---|
| 3 mm plywood | 2.7 to 3.2 mm |
| 3 mm acrylic | 2.8 to 3.1 mm |
| 6 mm plywood | 5.6 to 6.4 mm |
Enter measured thickness, not nominal thickness.
Kerf is the width of material removed by the cutting beam.
If kerf is not compensated:
- tabs may be too loose
- holes may be too large
- press-fit joints may fail
- dimensions may drift from the intended design
CutCase has three quick fit modes:
- loose
- standard
- tight
These scale the entered kerf. They are intended for quick iteration with the fit-test coupon.
- Enter measured material thickness.
- Enter an estimated kerf.
- Click
Fit Test. - Cut the coupon on the same material.
- Test loose, standard, and tight pairings.
- Pick the best fit mode.
- If all are wrong, adjust kerf and repeat.
- Export the full box after the coupon fits.
These are starting points only:
| Material | Thickness | Starting kerf |
|---|---|---|
| plywood | 3 mm | 0.10 mm |
| MDF | 3 mm | 0.10 mm |
| acrylic | 3 mm | 0.08 mm |
| cardboard | 2 mm | 0.15 mm |
Always test.
For lift-off lids:
- start with
0.3 mmclearance - increase clearance for tight lids
- decrease clearance if the lid rattles
- make sure lip strips are not too tall for the box height
The lid lip is meant to locate the lid, not to form a sealed mechanical lock.
Divider slots depend on thickness and effective kerf.
If dividers are too tight:
- increase kerf
- use loose fit
- increase material thickness only if measured value was wrong
- disable interlock slots and manually adjust if needed
If dividers are too loose:
- decrease kerf
- use tight fit
- verify actual material thickness
CutCase shows validation warnings in the production summary and stores the same warnings in SVG metadata. Treat these warnings as a preflight check, not as final machine approval.
Before cutting:
- keep holes away from panel edges
- avoid placing holes through finger joints
- keep large cutouts away from corners
- avoid thin strips of material between nearby holes
- check every feature in both SVG and 3D
Current validation checks include:
- cut features close to panel edges
- cut features smaller than the current kerf can reliably represent
- overlapping or nearly touching cut features
- tight lid clearance
- tall lid lips
- narrow divider compartments
- material and finger widths that create weak geometry
When importing SVG:
- verify millimeter scale
- verify line colors
- verify stroke width handling
- map cut, engrave, and mark operations to correct settings
- check whether the laser software interprets filled shapes differently
- run a frame or low-power preview before cutting
Use appropriate hold-down:
- magnets for steel honeycomb beds
- tape for light material
- weights outside the cutting path
- pins or tabs where safe
Warped material can break finger-joint accuracy.
Never leave a laser cutter unattended. Confirm extraction, air assist, and material safety before cutting.
Do not cut unknown plastics. PVC and some coated materials can release hazardous gases.
CutCase does not yet provide:
- dogbone reliefs
- full polygon offset kerf compensation
- machine bed packing
- material preset storage
- DXF layers
- automatic joint strength warnings