Tutorial · Welding
How to weld letters without losing the holes in a, e and o
This guide is not a workaround for WeldWords breaking your files — it explains the exact counter, dot and accent problems the maker is designed to avoid. You can use it to understand what good welded lettering should look like, then verify the clean holes before you cut.
5 minute read · Free to follow · 2 free batch exports + 1 free single export included
Short answer
The holes in a, e and o disappear when a weld fills counters instead of preserving them. WeldWords keeps inner contours open, preserves letter holes during welding, and attaches dots and accents where the geometry allows, so the exported SVG or DXF stays cut-ready.
Built into WeldWords
WeldWords preserves counters through the weld, keeps holes visible as inner cut paths, and handles dots, accents and multilingual marks before export instead of asking you to fix them later.
The tutorial explains what WeldWords is doing for you, plus what to check before you cut.
What you need
- Text converted to outlines
- Software that can weld or union paths
- A close look at every enclosed shape
- WeldWords, which preserves counters automatically
Step by step
Step 1
Understand what a counter is
The enclosed hole inside a, e, o, d, b, p and q is called a counter. It is a second path inside the letter, cut in the opposite direction, which is what tells the machine it is a hole rather than solid material. Lose the counter path and the hole either fills in solid or drops out as a loose island.
Step 2
Weld the outlines, not the holes
Only the outer boundaries of neighbouring letters should merge. A correct weld keeps every counter path intact as its own closed loop inside the welded outline. WeldWords preserves counters through every weld automatically, so the holes you see on screen are the holes that reach the laser.
Step 3
Watch where a connector crosses a counter
If a bridge or connector bar is drawn straight through a counter, it can merge with the hole and close it. Move the join point to solid material, or angle the bridge so it lands on the outer stroke, not the inside of a letter.
Step 4
Attach the dots on i and j
The dots on i and j are separate shapes that have no natural connection to the letter. Either bridge them to the stem with a tiny bar, or accept they will be loose pieces to glue back on. For keychains, always bridge them — a loose dot is a lost dot.
Step 5
Keep accents and diacritics attached
Accents on á, é, ñ, ü and similar marks are also separate shapes. WeldWords detects them and keeps them attached wherever the geometry allows, which matters most for multilingual name orders where every customer name may carry a different accent.
Step 6
Inspect every enclosed shape before exporting
Zoom in on each a, e, o, d, b, p, q. A counter that touches the outer edge is no longer a hole — it has merged with the outline and will cut as solid. Catch it on screen and you save a spoiled sheet.
Step 7
Mind tiny counters on small text
Very small counters in tiny text char shut on a laser because the beam is wider than the hole. If a counter is smaller than about 1.5 mm, increase the finished size or pick a more open font with larger internal holes.
Step 8
Export and confirm in your cutting software
Import the SVG or DXF and check the preview. Holes should show as inner cut lines inside each letter, not as separate loose parts. In LightBurn, toggle the cut preview to see both the outer cut and the inner holes clearly.
Tips that save material and time
- If a counter keeps filling in, the hole path direction was lost — re-outline the text and weld again.
- Very small counters in tiny text will char shut on a laser; increase the size or pick a more open font.
- Script fonts with tight loops are the most likely to lose counters, so check them first.
- Dots that stay separate are fine for painted signs but a nightmare for keychains.
- A counter smaller than your beam kerf will not survive — scale the name up.
- Check the lowercase 'e' first; its counter is the one that most often merges.
Questions people ask
Why did the middle of my 'o' disappear?
The weld merged the inner path into the outer shape. The hole has to remain a distinct path with the opposite direction to stay a hole.
Why did the centre of my letter fall out on the bed?
It cut correctly as a hole, but nothing held it in place — that is normal for a stencil. If you need it attached, add a small bridge between the counter and the outer shape.
Does WeldWords handle accents in other languages?
Yes. Accents, Arabic dots and Indic marks are detected and kept attached wherever the geometry allows.
How small is too small for a counter?
Roughly, any counter under about 1.5 mm risks charring shut on a typical diode or CO2 laser. If your text is that small, increase the finished size or choose a font with larger internal holes.
Do it now instead of reading about it
Type the word, let it weld, export the production file. Try 2 free batch exports and 1 single export, shared per account and internet connection.
Try it in the maker