Overcut

Overcut is a term used in several trades to describe cutting beyond the intended boundary of a workpiece or feature. It can refer to exceeding either depth, width, or contour, resulting in parts that are out of tolerance or joints with weakened geometry.

In machining and fabrication, overcut occurs when material is removed beyond what the design specifies. Causes include tool deflection, wear, incorrect tool length compensation, programming errors in CNC operations, or improper feeds and speeds. The result can be undersized parts, poor fit, or degraded surface finish. Mitigation strategies include verifying CAM data, checking tool offsets and wear, adjusting compensation, performing validation cuts, and applying finishing passes to restore accuracy.

In woodworking and routing, overcut describes cutting past a marked line, leaving a protruding edge or excess waste material that must be trimmed back. Corrective steps include adjusting layout marks, using appropriate bit paths, slowing feed rates, or making a cleanup cut to restore the intended contour.

In cutting and welding contexts, overcut can describe a kerf or cut that exceeds the designed boundary, creating grooves along edges or joints. Excess material removal can weaken the edge or alter tolerances. Preventive measures focus on proper cutting parameters, precise edge preparation, and careful control of the cutting process to maintain the intended geometry.