Why did it look fine on screen?
Screen preview shows fill, not path boundaries. Two shapes overlapping look identical to one merged shape until you cut them.
Troubleshooting
Your letters cut as separate pieces. Here is why.
The cutter follows path boundaries, not appearances. If two letters merely touch on screen, each one still has its own closed outline and the machine cuts around both — so the name comes off the bed in pieces. The fix is to make the strokes genuinely overlap and then merge them into one outline before export, which is exactly what WeldWords does as you type.
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The usual causes
Letters touch visually but their outlines never cross
The text was never converted to paths and merged
A union filled in the counters, so the weld was undone by hand
A formal script with flat stroke ends can never join on its own
The join was thinner than the material and snapped at the cut line
How to fix it for good
Tighten spacing until neighbouring strokes actually overlap
Weld the overlapping letters into a single closed outline
Add a bridge or underline bar where a gap will not close
Check the thinnest join against your material thickness
Cut one scrap test pair before committing the sheet
How it works
From typed words to a cut-ready file
Everything stays editable until you export, so one-off fixes never mean starting over.
- 01
Look at the outline, not the letters
Zoom in on each join. If you can see two separate boundaries meeting, it will cut as two pieces.
- 02
Pull the letters into overlap
Reduce letter spacing, or scoot one letter into its neighbour until the strokes cross.
- 03
Weld into one path
Merge the overlapping shapes into one outline while keeping the counters as holes.
- 04
Reinforce and test
Thicken thin joins or add a bar, then cut a small test on scrap before the full run.
Common questions
Will a thicker font fix it?
It helps, but only overlap plus a weld guarantees one piece. A thick font with gaps still cuts apart.
What about the dot on the i?
A dot is a separate contour by nature. It needs a small bridge to the letter body, or it will always cut free.
Try it on your own words.
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