A large design is not solved by simply cutting the file into rectangles. Every panel needs a known physical reference, a deliberate seam strategy and proof that neighboring output is disabled.
Build the master
Keep one untouched master at final physical size. Draw the usable laser area and clamp/keep-out zones on Tool layers. Add panel boundaries with a repeatable overlap or seam rule. Number panels and add two registration targets that remain accessible after each material move.
For a repeated pattern, place the seam through low-detail or naturally repeating areas when possible. For a cut contour, choose exact joining geometry rather than overlapping full-power cuts.
Create output copies
Duplicate the master for each panel. In each copy:
- Keep the master position unchanged.
- Enable only objects belonging to the current panel.
- Keep the required registration targets and non-output reference geometry.
- Use Cut Shapes or a mask appropriate to the output type; preserve an untouched master.
- Open Preview and confirm that no neighboring panel will process.
Name files in run order, for example 01-left, 02-center, 03-right. This prevents a correct panel from being output in the wrong physical position.
Register every movement
Secure the material so it cannot rotate. Use Print and Cut or the machine manufacturer's verified positioning procedure with two widely separated targets. Re-register after every sheet movement; an origin saved before the movement is not proof of current alignment.
