What is the Best CAD Software for Laser Cutting? What type of files are needed to program a successful laser cut product path?
When it comes to laser cutting, choosing the right CAD software is crucial for achieving precision, efficiency, and optimal results.
Although there are many softwares available that will generate CAD files, two of the most powerful CAD software options for laser cutting are SolidWorks and Fusion 360.
In this article, we’ll explore the features, pros, and cons of these software programs, particularly when using scan data in mesh-only format, and how CAD files are converted to G-code for laser cutting machines.
What is CAD and What Files Are Created?
CAD is an acronym for computer-aided design; a system of digital designs, processes, and assemblies to represent a system or product.
Data represented in a CAD model are parasolids. These files include dimensionally accurate data including hole diameters, undercuts, radii, and fillets. All of this information is imperative to a CAD software for laser cutting projects.
Generally speaking, CAD files are used for manufacturing, model rendering, architecture, system analysis, and other engineering feats. The files can be delivered in universal formats in order to be read by different CAD softwares.
Universal CAD files are available in STEP, IGES, and XT formats.
Experienced CAD engineers are able to draw parts and assemblies that dramatically decrease engineering time. These files can be changed quickly as well. Sometimes used interchangeably, 3D modeling is another term to describe the work done by a CAD engineer.
Before discussing the best CAD software for laser cutting, it does need to be noted that CAD files are universal; however, each software has its own native file format.
Choosing the Best CAD Software for Laser Cutting
Laser cutting requires detailed and precise designs generated in 3D. The quality of the final product heavily depends on the accuracy of the CAD files used.
Therefore, selecting the best CAD software can significantly impact the efficiency and quality of your laser cutting projects.
Initially choosing between softwares is going to be dependent on the education of the designer. What type of software did he or she learn on? What is the ease of design for the user? 
A good CAD designer will be educated in various manufacturing processes; CNC machining, laser cutting, injection molding, and others. Specifically their designs will be efficient in time and budget.
The top CAD software for laser cutting can also be dependent on budget, dealer availability, and how many licenses are needed. As with every modern day software, subscription packages are done on a yearly basis to control who has access to the proprietary software.
The two top CAD softwares for laser cutting include SolidWorks and Fusion 360.
SolidWorks for Laser Cutting
SolidWorks is an excellent choice for laser cutting projects due to several key features and capabilities that make the process efficient, accurate, and user-friendly. Here are some reasons why SolidWorks is highly regarded for laser cutting:
Precision and Accuracy:
SolidWorks provides precise control over dimensions and tolerances, which is crucial for laser cutting where exact measurements are essential for proper fitting and assembly of parts. (The software is even better when paired with 3D laser scanning!)
2D to 3D Integration:
It allows easy transition from 3D models to 2D drawings, which can then be used directly for laser cutting. This integration ensures that the 2D profiles accurately represent the 3D designs.
Comprehensive Design Tools:
SolidWorks offers a wide range of design tools that facilitate the creation of complex geometries, detailed designs, and intricate patterns which are often required in laser cutting projects.
File Compatibility and Export Options:
It supports various file formats (such as STEP, DXF and DWG) that are commonly used by laser cutting machines. This compatibility ensures seamless file transfer and reduces the risk of errors during the cutting process.
Sheet Metal Features:
SolidWorks has specialized tools for designing sheet metal parts, including bend allowances and flattening features. These tools are particularly useful for creating accurate flat patterns ready for laser cutting.
Simulation and Analysis:
It provides simulation tools to analyze the design for potential issues before cutting, helping to minimize waste and avoid costly mistakes.
Material Library:
The software includes a comprehensive material library, allowing designers to assign materials with specific properties (such as thickness and type) which are critical for laser cutting parameters.
CAM Integration:
SolidWorks can integrate with CAM (Computer-Aided Manufacturing) software, which aids in generating the tool paths required for laser cutting. This integration streamlines the process from design to manufacturing.
Collectively, SolidWorks also has a large user community and extensive support resources, including tutorials, forums, and customer service, providing assistance and knowledge sharing for troubleshooting and optimization.
These features collectively make SolidWorks a powerful tool for designing and preparing projects for laser cutting, ensuring high precision, efficiency, and ease of use throughout the process.
Cons of SolidWorks:
1. Cost:
SolidWorks can be expensive, which might be a barrier for small businesses or hobbyists.
2. Resource-Intensive:
The software requires significant computing power, which means you’ll need a high-performance computer to run it efficiently.
Fusion 360 for Laser Cutting
Fusion 360 is also an excellent choice for laser cutting projects due to its versatile and integrated design and manufacturing capabilities. Here are some reasons why Fusion 360 is highly regarded for laser cutting:
Integrated CAD, CAM, and CAE:
Fusion 360 combines Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM), and Computer-Aided Engineering (CAE) into a single platform. This integration streamlines the workflow from design to manufacturing, making it easier to prepare models for laser cutting.
Cloud-Based Collaboration:
Being cloud-based, Fusion 360 enables easy collaboration and sharing of designs. Multiple users can work on the same project, making it ideal for team projects and remote work.
2D and 3D Design Capabilities:
Fusion 360 allows for the creation of detailed 2D sketches and complex 3D models. These designs can be easily converted to 2D profiles needed for laser cutting.
Sheet Metal Design Tools:
Similar to SolidWorks, Fusion 360 has robust sheet metal design tools. These tools enable the creation of accurate flat patterns and take into account bend allowances and other factors important for laser cutting.
CAM Integration:
Fusion 360 includes built-in CAM functionality, allowing users to generate the necessary toolpaths for laser cutting directly within the software. This feature simplifies the process from design to production.
Material Library:
Fusion 360 has an extensive material library that includes various materials with their properties. Users can assign these materials to their designs, which is crucial for determining the cutting parameters.
User-Friendly Interface:
The interface is intuitive and user-friendly, catering to both novice and experienced users. Fusion 360 also provides extensive tutorials and documentation to help users get the most out of the software.
Affordability:
Fusion 360 offers competitive pricing and flexible subscription options, making it accessible to a wide range of users, from hobbyists to professionals. These features make Fusion 360 a powerful and versatile tool for laser cutting projects, ensuring efficient workflow, precision, and ease of use.
Cons of Fusion 360:
1. Internet Dependence:
Since it’s cloud-based, a stable internet connection is essential, which can be a drawback in areas with unreliable internet.
2. Learning Curve:
While user-friendly, some advanced features may still have a steep learning curve for new users.
Scan Data With CAD Software for Laser Cutting
When working with scan data in a mesh-only format, both SolidWorks and Fusion 360 have their strengths and weaknesses.
Scanned data can provide a high level of accuracy for complex shapes and surfaces that are difficult to model manually. This high level of detail can be particularly beneficial for laser cutting projects, where precision is crucial.
Additionally, using scanned data can significantly reduce the time required for creating detailed models, as it eliminates the need for manual measurements and modeling. This time-saving aspect can accelerate the design process and improve efficiency.
However, there are also downsides to using scan data. Scan data files in mesh format can be extremely large, which can slow down the processing speed and require significant storage space. This can be a major drawback when working with complex models.
Furthermore, editing and refining mesh data, a process called reverse engineering, can be complex and challenging, especially when trying to achieve high precision for laser cutting. Compatibility issues can also arise, as not all CAD software handles mesh data well. This can lead to the need for additional software to convert the data into a usable format. 
Fusion 360 and SolidWorks with 3D Scans
SolidWorks supports importing mesh data, but its tools for editing and refining mesh models are not as advanced as some other software specifically designed for handling mesh data.
Converting mesh to solid bodies in SolidWorks can be cumbersome and may require additional steps to achieve the desired results. This can make the process more time-consuming and less efficient.
In contrast, Fusion 360 provides better tools for working with mesh data compared to SolidWorks. It offers features for editing and repairing mesh models, making it easier to convert mesh data into solid models that can be used for laser cutting.
Fusion 360’s integrated environment for CAD and CAM also streamlines the process from design to manufacturing, offering a more seamless workflow. This makes Fusion 360 a more efficient choice for projects that involve working extensively with scan data.
Converting CAD Files to G-code for CNC Machines
Once you have your design ready in SolidWorks or Fusion 360, the next step is to convert the CAD files into G-code, which is the language CNC machines understand to perform laser cutting.
Steps to Convert CAD Files to G-code:
1. Export the CAD File:
First, export your CAD design from SolidWorks or Fusion 360 in a format compatible with your CNC machine, such as DXF or STL.
2. Import into CAM Software:
Import the exported file into CAM software. Both SolidWorks and Fusion 360 have integrated CAM capabilities, simplifying this step.
3. Set Cutting Parameters:
Define the cutting parameters in the CAM software, including the cutting speed, power, and path. These settings will vary depending on the material and thickness.
4. Generate Tool Paths:
The CAM software will generate the tool paths for the laser cutter based on the defined parameters.
5. Convert to G-code:
Finally, the CAM software converts the tool paths into G-code, which can then be uploaded to the CNC machine for laser cutting.
SolidWorks CAM, included in SolidWorks, provides seamless integration for converting designs into G-code. It offers customizable machining strategies and supports various CNC machine types.
Fusion 360’s integrated CAM functionality is one of its standout features. It allows users to quickly generate G-code from their designs, with advanced options for optimizing the cutting process. The cloud-based nature of Fusion 360 also means you can easily collaborate and share G-code files with your team.
So What is the Best CAD Software for Laser Cutting?
Choosing the best CAD software for laser cutting depends on your specific needs and preferences. SolidWorks and Fusion 360 both offer robust features and capabilities, making them excellent choices for laser cutting projects.
While SolidWorks is known for its comprehensive tools and simulation capabilities, Fusion 360 stands out with its cloud-based platform and integrated CAD/CAM/CAE environment.
When working with scan data in mesh-only format, Fusion 360 has an edge due to its advanced mesh editing tools. However, both software programs can convert CAD files to G-code efficiently, streamlining the design-to-manufacturing process.
Ultimately, the best choice will depend on your budget, the complexity of your projects, and your preferred workflow. By leveraging the strengths of SolidWorks or Fusion 360, you can enhance the precision and efficiency of your laser cutting projects, achieving optimal results every time.
