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How SendCutSend Determines Minimum Hole Size and Bridge Distance- Office Hours Chapter 5.2

2026-07-27 · 16:59 UTC ·SendCutSend ·1 min read

Brief

SendCutSend (tutorial) uses material- and thickness-specific test cards across laser and CNC processes to show how hole size, bridge width, heat input, tool diameter and material behavior determine whether features cut cleanly or fail. The hands-on demos (stainless steel and ABS) establish empirical minimum hole and bridge guidelines so parts work on the first try.

Why it matters

SendCutSend’s material-specific tests (published 2026-07-27) show minimum hole size changes with material and thickness: thicker stainless-steel examples (00:45, 01:13) experienced warping and bridge burnout when holes were too small due to greater heat absorption.

Key details

  • Bridge width directly affects heat buildup, warping, and part stability: narrow bridges are prone to burnout under higher heat input, so minimum bridge distances are set from empirical test cards across machine types and processes.
  • For routed plastics (ABS) the router bit diameter controls minimum feature size: the CNC router demo (01:43) demonstrates chatter, bending, and breakage (02:10) when tool diameter, feed, and part thickness exceed stable cutting limits.
Source evidence

In this lesson we answer a common design question about how we determine minimum hole sizes and minimum bridge distances listed in our guidelines.

Using material specific test cards for different thicknesses machine types and processes we demonstrate how hole size, bridge width, heat input, tool diameter and material behavior all affect whether a feature cuts cleanly or fails.

In this episode you will learn how to:
• Understand why minimum hole sizes change with material and thickness
• See how bridge width affects heat buildup warping and part stability
• Recognize how thicker materials absorb heat differently than thin sheet
• Learn why some small holes fail due to laser limits or tool diameter
• Understand how router bit size controls minimum feature size in plastics
• See how internal testing sets you up for successful parts on the first try

⏰ Timestamps ⏰
00:00: Introduction to the question
00:45: Stainless steel examples, failures, and warping
01:13: Thicker material example, small holes, bridge burnout
01:43: CNC router example with ABS
02:10: Chatter, bending, and breakage

If you want your questions answered in a future episode drop them in the comments of the main lessons at sendcutsend.com education

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SendCutSend Education was filmed and edited by Keaton Bowlby.

Channel: SendCutSend
Published: 2026-07-27
Video URL: https://www.youtube.com/watch?v=c5A6slN5qPA