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Stickers with Borders: How to Fix Extra Internal Cut Lines in Silhouette Studio

If you're trying to add a white border around stickers in Silhouette Studio and now you have a bunch of unwanted internal cut lines - there's an easy fix. 

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Trying to select and delete those little islands isn't possible without deleting the entire offset.  They're one of the most common frustrations people run into when making white border stickers in Silhouette Studio. Here's exactly what they are and how to get rid of them.

Why "Offset Islands" Happen

When Silhouette Studio creates an offset around a design, it extends every original cut line out by a pre-determined distance. Overlapping offset lines will weld together, but if there's enough room for a full offset on internal cut lines, you'll get these internal islands. 

Note: I have increased the line weight so you can more easily see the unwanted cut lines.

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Think of it like water filling up around rocks. If the water level is low (small offset distance), it fills each little pocket separately. If the water level is high enough (larger offset distance), all the pockets merge together into one solid shape and no islands form. The more detailed your design, the more likely you are to get islands at smaller offset distances.

The easy fix: Release Compound Path

When Silhouette Studio creates an offset, all the pieces — the main border and every island - are part of a single layer. They are a compound path.  That's why clicking on an island selects the whole thing. You need to remove the compound path before you can delete individual pieces. Essentially you need to release the single layer into multiple layers. 

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To do so, right-click on the offset and select Release Compound Path. Now everything that was part of that offset is a separate, individually selectable shape. 

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To keep the white border offset, but delete the extra internal cut lines, click anywhere on the main outer border to select it, then hold Shift and click each island to deselect it, leaving only the islands selected. 

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Hit Delete and they're gone.

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Alternative Fix: Increase your Offset Distance

If you haven't applied the offset yet, the easier solution is to just increase the offset distance until the islands disappear on their own - but sometimes that offset distance is just too much.  

When the distance is large enough, the offset self-welds across the tight gaps and the islands never form. For most sticker designs a distance of around 0.1" to 0.15" is enough to avoid them, though it depends on your specific design.

This works in both Silhouette Studio V4 and V5.

See the Full White Border Sticker Process

Knowing how to remove unwanted cut lines or island is one piece of the white border sticker workflow - but there's more to it than just the offset. You also need to set up your background correctly so you can actually see the white border while you're working, manage your cut lines so only the border layer cuts and not every edge of your design, and know when you actually need to fill the offset with white versus when the material handles it for you.

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That full tutorial start to finish in Silhouette Studio V5 is covered in the latest Silhouette U video. If you're a member, you can watch it here. If you're not a member yet, you can preview that video and all the rest in the Silhouette U video library (700+ step-by-step tutorials). Plus as a member, you'll geet same-day support from me (Melissa), and tools built specifically for Silhouette users . 

Learn more about Silhouette U here →


Note: This post may contain affiliate links. By clicking on them and purchasing products through my links, I receive a small commission. That's what helps fund Silhouette School so I can keep buying new Silhouette-related products to show you how to get the most out of your machine!






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