How to Use LightBurn Boolean Tools for Interlocking Parts
LightBurn has Boolean shape operations that let you combine, subtract, and intersect vectors. Essential for creating interlocking parts like tabs and slots, boxes, and press-fit assemblies.
The Boolean Tools
Located in Edit → Boolean Tools or the Boolean panel:
| Tool | What It Does |
|---|---|
| Union | Merges two shapes into one |
| Subtract | Removes one shape from another |
| Intersect | Keeps only the overlapping area |
| Exclude | Removes overlapping area from union |
Project: Tab and Slot Joint
Create a perfect-fit tab and slot for box construction:
Step 1 — Design tab:
- Draw rectangle for the tab (e.g., 10mm wide × 5mm tall)
- This becomes the male tab on one panel
Step 2 — Create matching slot:
- Copy the tab rectangle
- Add 0.1mm to all dimensions (for laser kerf clearance)
- Position on the edge of the receiving panel
- Select panel shape and slot rectangle
- Boolean → Subtract — slot rectangle cuts into panel shape
- The slot is now cut out of the panel exactly
Step 3 — Test fit: Cut one tab and one slot in scrap. They should fit snugly. Adjust the clearance offset if too tight (increase) or too loose (decrease).
Kerf Compensation
The laser removes material equal to the beam width (kerf) — typically 0.1–0.15mm for the Ray5.
For tight fits, subtract half the kerf from tab width and add half to slot width.
Box Joint Design
For a simple finger-joint box:
- Design a single finger (tab + slot pair)
- Duplicate along the edge
- Use Boolean subtract to cut all the slots from the panel in one operation
LightBurn's Grid Array duplication makes this fast.
Living Hinges
Boolean tools help design flexible hinge patterns. Draw the cut pattern, subtract from the panel, test flex before cutting production pieces.