Kerf Offset: Compensate for Material Removed by the Cut

Why this matters

Measure real cut width and compensate fit-critical parts instead of scaling the entire design blindly.

How it works

• Kerf is the width of material removed by the cutting process.
• Fit-critical designs can require offset compensation so inside and outside dimensions remain closer to the intended size.
• Kerf depends on material, focus, power, speed, lens and other machine conditions.

Practical workflow

1. Cut a dedicated kerf test on the actual material and thickness.
2. Measure the resulting pieces with a suitable measuring tool.
3. Calculate or derive the effective kerf from the test rather than eyeballing a gap.
4. Apply compensation to the relevant cutting layer or geometry.
5. Cut a small joint sample before producing a full assembly.

What to watch for

• Kerf is not a permanent property of the laser; it changes with process conditions.
• Compensating the wrong direction makes fit worse.
• Do not scale an entire design as a substitute for correct kerf compensation.