Export Sheet Metal Flat Pattern for Laser Cutting in SolidWorks

To export a sheet metal flat pattern for laser cutting in SolidWorks, first create the flat pattern by right-clicking the sheet metal feature and selecting Flatten. Then, save or export the flat pattern as a DXF or DWG file using Save As and choosing the appropriate format for laser cutting.

Syntax

In SolidWorks, exporting a sheet metal flat pattern involves these steps:

• Flatten: Right-click the sheet metal feature and select Flatten to create the flat pattern.
• Save As: Use File > Save As to export the flat pattern.
• File Type: Choose DXF (*.dxf) or DWG (*.dwg) format, which are standard for laser cutting machines.
• Options: Configure export options to include only the flat pattern geometry.

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1. Right-click sheet metal feature > Flatten
2. File > Save As
3. Select file type: DXF or DWG
4. Choose export options
5. Save file

Example

This example shows how to export a flat pattern as a DXF file for laser cutting:

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1. Open your sheet metal part in SolidWorks.
2. In the FeatureManager design tree, right-click the <Sheet Metal> feature.
3. Click <Flatten> to view the flat pattern.
4. Go to <File> > <Save As>.
5. In the <Save as type> dropdown, select <DXF (*.dxf)>.
6. Click <Options> and ensure <Entities to Export> is set to <Selected bodies> or <Flat Pattern>.
7. Click <OK>, then <Save>.
8. The DXF file is now ready for laser cutting software.

Output

A DXF file containing the flat pattern geometry is saved to your chosen location, ready for laser cutting.

Common Pitfalls

• Not flattening first: Exporting without flattening will save the 3D model, not the flat pattern.
• Wrong export options: Failing to select the flat pattern or correct entities can cause incomplete or incorrect files.
• Ignoring units: Make sure units in SolidWorks match the laser cutter's requirements to avoid scaling issues.
• Missing bends or reliefs: Verify that all necessary features are included in the flat pattern before export.

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/* Wrong way: Exporting without flattening */
// User tries to save as DXF directly from 3D model
File > Save As > DXF
// Result: 3D geometry exported, not flat pattern

/* Right way: Flatten first */
Right-click Sheet Metal feature > Flatten
File > Save As > DXF
Select flat pattern entities
Save file

Quick Reference

Step	Action	Tip
1	Flatten sheet metal	Right-click feature, select Flatten
2	Save As DXF/DWG	Use File > Save As and pick correct format
3	Set export options	Choose flat pattern entities only
4	Check units	Match SolidWorks units to laser cutter
5	Save file	Confirm location and filename

Key Takeaways

Always flatten the sheet metal part before exporting to get the correct flat pattern.

Export the flat pattern as a DXF or DWG file for compatibility with laser cutting machines.

Check export options to include only the flat pattern geometry to avoid errors.

Verify units in SolidWorks match the laser cutter's requirements to prevent scaling issues.

Review the flat pattern for all necessary features before exporting.