Hi Chris, can you please post the DXF file for the one that had dropouts so I can see if there's anything wrong with the file itself?

re:
> Is there a way to output these so there will be a greater number of smaller
> segments joined to create these shapes?

My best guess is that you actually have too many small segments and the laser cutter control software is just ignoring ones under a particular size.

If that's the case you would probably get better results with a looser angle like say 5 degrees.

The other thing you could try is to use Edit > Separate on your rectangles with rounded corners before doing the export. That's because if an individual curve is a circle or arc it will be exported as a special CIRCLE or ARC entity in the DXF file rather than a polyline with a lot of little segments in it. If the arc is part of a longer joined curve then it will get the polyline treatment instead. I've been thinking about doing that kind of separation automatically for DXF export.

But if you could please send your DXF file I'd like to check it to see if there's any problem there.

- Michael