

I released the paths, ungrouped, united, then drew in the center of the O and minus front then unite then made the compound path again, didn't fix it. I tried created a new one by live tracing and making compound paths and what not and had the same problem with all the O's in the image. Illustrator treats a compound path as a single object. It is VERY IMPORTANT to make sure that the two objects are compound paths (or single objects) and not groups or you'll have no luck. This punches the top object through the bottom without any funny business. If you can't just unite objects which is the case of some of these complex designs (each color being a compound path with multiple holes) I usually will make sure each object that I want to combine is it's own compound path and then color the top a different than the second and use the "minus front " option from the pathfinder rather than merge. I don't think this would cause a double cut but it's weird. I am using CS5 so it's possible that when I opened your file that it messed that up on my end during the file conversion to my version. Meaning that the ends of the paths are not connected so you have a line all the way around but it's not actually a box. The only thing I see that is a bit unusual is that the inside of several of your letters are not completed paths. Sometimes you can also just ignore them at cut time by making sure you don't have any uncolored items selected in your cut by color options but I get them gone so they don't come back to get me some later cut. You can fix these anomalies by selecting one (I use the layer stack to select one and see on the workspace if it was one of the areas that should not be a separate object) and then I use the select>same fill color option and it will select all of them in the design and then just delete them, Your holes should still be there but without the additional object that was messing with your cutter. If you look over in your layer stack you can see in the tiny previews if something has no color.

If you try to use Unite rather than merge it usually doesn't cause this. Merge leaves the overlap areas as an object in case you wanted to fill it with a diff color or something. Most commonly caused by using the merge function.

What you have is unfilled paths in some of your 'holes". Illustrator is SO powerful that it doesn't automatically assume anything for you in most cases. PLEASE tell me if i'm wrong in doing things, I only have been working with vinyl and my graphtech for 7 days. I figured Illustrator is a powerful graphics application so it would be easy to do everything I need.

I am more trying to figure out the design to cutter process than the weed and apply (as i don't have those tools yet). I also have some squeegee's coming and just applied pressure on this one by hand so i know it is horrible. Please see the attached image of my first print, to make things worse, it seams i don't have the correct transfer tape for multi layer designs as it kept bringing up all the layers and just overall gave me a hard time. I normally just pick a font within illustrator and use that but this time I was testing taking a font and converting it in case a customer comes at me in the future with something funky. I thought it was going to be a simple 2 part cut and apply until i had those problems. Maybe i misunderstood your response and i should have explained the design.ġst cut was on the blue for a solid outline, no letters cut out of it.Ģnd cut was on the white for the letters and the "snow"
