Cutting guidelines for tubes


Versie 1.0 10/10/2017


Ducts (square and rectangular) must be drawn in the corners as follows: outside radius = 2x wall thickness and inner radius = 1x wall thickness. The value “2” is the average value of the size of the radiuses specified in the standard.

 In case of aluminium tubes (square and rectangular), the corners must be drawn as follows: outer radius = 0.5 and inner radius = 0.

247TailorSteel cuts 2.5D. This means that the cutting edge of the ducts is perpendicular to the material (centre-orientation). In case of tubes, it is directed towards the centreline. Some examples are discussed later in this manual. The software of the 247TailorSteel converts the 3D-cutting edges into 2.5D-cutting edges.

Wall thickness options:

  • Aluminum(tube): up to and including 3 mm
  • S355 (st.52): up to and including 6 mm
  • Stainless Steel: up to and including 5 mm

Dimension options:

  • Tube diameter: minimum Ø20.0 mm and maximum Ø219.1 mm.
  • Duct: minimum square 20x20 mm and maximum 200x200 mm.

Maximum weight of the product per metre: 32 kg.
Maximum length to be laser cut from one piece: 5,800 mm.


The tolerances on the cut contour, centring of the cut contour and on the total length amount to +/- 0.2 mm. The tolerance is strongly influenced by a number of factors, such as:

  • The form and dimension tolerance on the tube and duct
    These are described in the relevant standard sheets (for example EN10219). Deviations from the nominal tube/duct dimension have a direct influence on the centring of the cut contours.
  • The dimensions and rigidity of the tube and duct
    Small and narrow ducts are flexible and move a lot in the machine during laser cutting. This can cause deviations in the dimensions and cutting patterns.
  • Heat-input through contours
    When many contours are cut into a tube or contour, this gives a lot of heat-input and the tolerances can deviate. This also causes discoloration of the material.

Welding seam position

When loading the machine, the ducts are loaded randomly (sometimes a complete bundle). This makes it possible that the welding seam can be on different sides of the same product. This means that the welding seam can be on different sides of the same product:

Within 12 hours after placing the order, we would like to receive a PDF drawing on which the position of the weld seam and the corresponding position no. of the article are clearly stated. You can send this PDF to


Example - The orange arrow represents the position of the weld seam

Splash on the inside of the tube/duct

The liquid material that forms during laser cutting can attach on the inside of the opposite side; this is also referred to as splash. The dimension of the splash depends on a number of factors:

  • Internal diameter of the tube/duct
    The larger the diameter, the smaller the splash.
  • Wall thickness of the tube/duct
    The larger the wall thickness, the bigger the splash.
  • Internal surface of the tube/duct
    A smooth - greasy tube/duct is less sensitive to the attachment of a splash than a rough - dry tube/duct.


247TailorSteel only engraves functionally, for positioning or identification. Blind holes are automatically recognized as engraving. If desired, Sophia® can convert a cutting contour into an engraving*.

*Engraving is not possible with aluminum pipes


2.5D-laser cutting

247TailorSteel cuts 2.5D. This means that the cutting edge is perpendicular to the material (centre-orientation). The software of 247TailorSteel converts 3D-cutting edges into 2.5D cutting edges. This means that a product can be cut different to the drawing. See the examples below for an impression:


Example - drawn image


Example - 2.5D-drawing

2.5D cut holes in round tube

Example - drawn image


Holes in round tubes are cut at right angles to the material (centre point). As a result, the holes are cut differently than drawn. Holes that are drawn cylindrically (blue lines in the image) are cut elliptically (orange lines in the image). The diameter of the round hole, measured on the inside diameter of the round tube, corresponds with the diameter of the drawn hole. The diameter of the hole measured on the outside diameter of the tube is bigger and ellipse shaped. These holes are not suitable for, for example, wire tapping.

However, if you require that the hole is cut cylindrically, please inform us within 24 hours of placing the order and provide a clear PDF drawing that explicitly indicates which operations need to be cut cylindrically. 

ATTENTION: The diameter of cylindrical holes in round tubes has an upper limit and can not exceed approximately 0.5 x tube diameter.

2,5D-laser cutting in mitre

247TailorSteel cuts 2.5D. This means that the cutting edge is perpendicular to the material (centre-orientation). In case of products that are drawn in mitre, that leads to a groove being created in the outer corner (see images below). These grooves are often filled during welding.




Example - ducts


Example - tubes

Laser cutting of U-shaped products

U-profiles and segments cannot be cut with 247TailorSteel. In this instance, the system does not recognise a tube or duct. It is important that the full circumference of the tube is present somewhere in the drawing. One of the solutions for this is to draw a “ring” of the starting material alongside and to connect this with a small connection (see images). To this end, please note the available material. To this end, look at the “material summary for tube/duct”. The solutions referred to can also be applied to round tubes. If indicated by the Customer, the additional “ring” and/or the “bridge” can be omitted during laser cutting in many cases.



Tube-guidelines_15In addition, there is the option of choosing to draw an additional “bridge” to get the required full circumference (see image).

Connections of tubes

Connections of tubes frequently give problems when drawn in 3D. The online tool, Sophia®, does not always convert the cutting lines correctly, so that the mutual connection of the tubes is not “seamless”. In some cases, this can be solved internally, but new drawings are usually requested. Look at the example below of a 3D-drawing with the products as a result and an example of a tube connection drawn fully in 2.5D.



Example - 3D-drawing and the actual product


Example - 2.5D-drawing and the actual product

Every order is unique to us. It is therefore also important that, even in case of recurrent products, the specifications, such as the position of the welding seam or the engraving, are again indicated.


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