Tiling with an Overlap
I have been cutting large stencils for gyms for a client for a long time and there's a little issue I haven't been able to figure out but have just made do. These are large stencils, so I design in Illustrator at 1:10 scale. For reference, the circle in the attached image is 12 feet. When approved, I take to our Roland VS640i using Versaworks, scale 1000%, and then tile as the material only has about 47" of usable width. So as an example in reference to the attached image, I'll tile into 3 panels with a 1/2" overlap. It's great, but the software doesn't finish the cuts where it cuts through artwork, so I cut it manually afterwards. See the other two images. The middle panel with the sides open is what I'm getting, and the other is what I ideally want. I think I've exhausted my options of having Versaworks do the work for me, so the next step is to manually tile each panel before sending to the printer.
I just want to see if there's a quicker way to get the end result. If it was as simple as cutting artwork into 3 panels, that would be no problem, but the overlap seems to add several steps. I need the overlap. So my question is how can I tile artwork maintaining an overlap.



