Overview

If a layout file crashes, freezes, or fails to load in the Dusty Portal or the iPad App, the issue is almost always related to file size, complexity, or unsupported content.

This article explains the most common causes, how to identify them, and what steps will and will not resolve the issue.

Symptoms / What You’ll See

• The Portal fails to finish loading or publishing a file
• The Portal loads but becomes unresponsive
• The iPad App crashes when opening a project
• The iPad App loads the file, but freezes or closes unexpectedly
• Sync completes, but the file cannot be opened on the iPad

Why This Happens

File Is Too Large or Too Complex

Dusty files are optimized for field performance. Extremely dense or complex files can overwhelm the Portal or the iPad App during processing.

This is most commonly caused by:

• Excessive object count
• Too many small line segments
• Over-detailed backgrounds or reference geometry

File with over 10,000 Obstacles

Dusty supports up to 10,000 obstacles per file.

When obstacle counts approach or exceed these levels:

• Files may fail to publish in the Portal
• The iPad App may crash on load

Best practices for Obstacles:

• Columns: Remove hatches before exporting, so columns are single shapes.
• Slab Edges: Have one continuous boundary instead of multiple line segments.
• Sleeve locations: Create one circle per sleeve instead of multiple circles.

Unsupported or Corrupt Source Geometry

Files may crash if they contain:

• Corrupt AutoCAD entities
• Zero-length lines or malformed splines
• Exploded blocks with excessive segmentation
• Unitless or mixed-unit geometry

These issues often originate in the source AutoCAD or Revit export.

Extremely Large Project Areas

Layouts that span very large distances, especially when objects are far from the main work area, can cause memory and rendering issues.

Common examples include:

• Background geometry miles away from the active layout
• Survey data or references left in the model unintentionally

How to Fix or Prevent

1: Confirm Object and Obstacle Count

• Review how many obstacles are included in the file
• Remove unnecessary obstacles
• Avoid importing repeated or redundant obstacle geometry

2: Reduce File Complexity

• Remove background layers not required for layout
• Simplify overly segmented linework
• Avoid exploded text, hatches, or dense reference geometry

3: Limit Project Extents

• Remove geometry far outside the active print area
• Trim files to the minimum necessary footprint

Keeping all geometry close to the work area significantly improves stability.

4: Validate Units and Geometry

• Confirm the source file uses consistent, defined units
• Clean the file to remove corrupt or zero-length entities
• Re-export the file after cleanup

Re-uploading without fixing the source file will not resolve crashes.

5: Split Large Projects

If a single file is too large or complex, splitting it is the most reliable fix. 

Recommended guidelines when splitting files:

• Dusty file size: Try to keep each published Dusty file (including all Dusty data and associated CSVs) under 8–10 MB in the Portal
• CSV and obstacle count: Try to stay under 10,000 points across all CSVs for printing trade points.

If you approach these limits, split the project before publishing.

Common and effective ways to split files include:

• Floor-by-floor layouts
• Phasing or zone-based layouts

Staying below these thresholds improves stability in both the Portal and the iPad App and reduces the risk of crashes.

What Will Not Fix This Issue

• Rebooting the iPad
• Reinstalling the Dusty App
• Re-uploading the same file without modification
• Attempting to force the file to load

If the file exceeds system limits or contains problematic geometry, these actions will not resolve the crash.

When to Contact Dusty

Contact Dusty Support if with the source CAD or Revit export, a brief description of where the crash occurred (Portal or iPad) and any recent file changes if:

• You are unsure whether the obstacle limit is being exceeded
• The file continues to crash after simplification
• You need guidance on splitting or restructuring files

Best Practices

• Keep files focused on the printable scope only
• Avoid unnecessary obstacles and background geometry
• Split large projects early instead of pushing system limits
• Test new workflows with a small area before scaling up
• Use the Dusty Academy for file prep guidance and refreshers