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Laser-Cut Bolt Holes: Clearance Holes vs Tapped Holes

When you draw a hole in a laser-cut plate, start with a practical question: does the bolt pass through it, or does the screw need to engage a thread in the plate? Those are different requirements. A circular outline in a DXF file does not, by itself, explain which result you need.

For brackets, mounting plates and other metal parts, identifying the hole’s purpose before ordering helps you communicate the job clearly. This guide explains the distinction and the information to provide when requesting metal laser cutting from Shug in Mooroolbark.

What is a clearance hole?

A clearance hole allows the fastener to pass through the part rather than screw into it. The thread may engage a nut or another component on the other side. The hole size should come from the intended fastener, the required fit and the assembly design.

Do not assume that the nominal bolt size is the finished hole diameter. Check the applicable fastener information and drawing requirements. If several plates must line up, specify the positions and any critical fit requirements as well as the diameters.

What is a tapped hole?

A tapped hole contains an internal thread that engages the screw. Creating that thread is a separate requirement from cutting a circular opening through sheet metal. For a threaded feature, the thread specification and preparation of the hole both matter.

Sandvik Coromant’s tapping guidance calls for selecting suitable taps and drills for the material and hole. There is no single hole size that suits every thread or material. Confirm the preparation with whoever will perform the threading before finalising the cutting geometry.

A DXF circle does not include every hole feature

A plain circular cut path does not tell the cutting process to produce threads, a countersink or a counterbore. In CAD software these are distinct features: Autodesk’s hole reference separates simple, clearance and tapped holes, along with countersink and counterbore options.

If the finished part needs one of those features, provide a dimensioned drawing or clear notes alongside the cutting file. Ask for direct review before ordering. Do not assume that drilling, tapping or other machining is included in an instant laser-cutting quote.

What to send with your enquiry

  • The current DXF or DWG file and its revision reference.
  • The material, sheet thickness and quantity required.
  • Whether each critical hole is for clearance or for a later threaded feature.
  • The specified hole dimensions and positions; include the thread designation where relevant.
  • Any separate finishing or machining requirements, and who will carry them out.

For a mating assembly, explain what the part connects to. Avoid changing hole diameters by guesswork to compensate for cutting. Discuss critical dimensions and the proposed production sequence before committing to a batch. Our DXF preparation checklist covers scale, contours and duplicate lines.

Get a quote with the requirements clear

Shug laser cuts mild steel up to 10 mm, stainless steel up to 3 mm and aluminium up to 2 mm. These cutting limits do not establish the suitability of a threaded joint or guarantee a particular hole tolerance.

For cutting-ready parts, upload your DXF or DWG for an instant quote. If the drawing needs clarification, contact Shug for direct review. You can also read our laser-cutting design guidelines before preparing the files.