What format and settings should I use to export from Adobe Illustrator so my design imports cleanly?

What the software wants from Illustrator

The software reads path geometry, not artwork styling. The official FAQ advice for Illustrator and similar programs is to convert vector geometry and text to curves, switch off pattern and color fills, and export, preferably as EPS. AI files are also supported, and both AI and EPS are placed with the lower left corner of the design at X0, Y0. Imported vectors arrive at the size they were drawn, so draw at real size.

Steps

1. Set the artboard and artwork to the real finished size in inches or millimeters.
2. Select all text and choose Type > Create Outlines. Keep an editable copy of the file first, because outlined text can no longer be retyped.
3. If a line is supposed to carve at its drawn thickness, select it and choose Object > Path > Outline Stroke (see the entry on thick lines that import as thin single lines).
4. Remove fills, patterns and effects you do not need.
5. Choose File > Save As and pick **Illustrator (.AI) or Illustrator EPS (.EPS). In the AI options, leave Create PDF Compatible File** checked. Adobe describes it as storing a PDF representation inside the file for compatibility with other apps.
6. In the software use File > Import > Import Vectors / Bitmaps to bring the file into an open job, or open it directly to start a new job.

If you must use SVG or DXF

• SVG (File > Export > Export As): set Font to outlines (Adobe calls outlines the most compatible choice), raise Decimal for more precise node positions, and leave Responsive unchecked. Adobe states that with Responsive checked no absolute size values are written, which removes the size information you want to keep.
• DXF: check the Scale units so the numbers mean what you expect, and turn on Outline Text. The official FAQ warns that DXF cannot hold Bezier curves, only arcs and straight lines, so AI or EPS is the better choice for flowing artwork.

Pro tips

• In the DXF dialog, Export Selected Art Only writes a blank file if nothing is selected.
• After importing, check one known dimension with the Measure tool before you toolpath (see the entry on scaling a drawing to a real measurement).
• Adobe now describes EPS as an older format, while the software maker's FAQ still prefers it. Both EPS and AI import, so use whichever gives you the cleaner result.