Nesting Software

The example above was chosen because it demonstrates familiar shapes arranged in an unfamiliar configuration. Now imagine software capable of taking virtually any collection of outline shapes, automatically rotating and positioning them to maximize the number of parts that can be cut from a sheet of material.

It quickly becomes clear that this is a task best handled by a computer rather than manually. Nesting optimization requires substantial computational processing to evaluate countless layout possibilities and identify the most efficient arrangement.

Typically, nesting software imports CAD files containing the profiles of the parts to be cut. Because nesting operates in two dimensions, standard file formats such as DXF files are commonly used.

After importing the part outlines, the operator provides additional information, including:

The quantity required for each part
The minimum spacing between parts
Material and cutting-process constraints

Part spacing requirements vary depending on the cutting method being used, such as routing, plasma cutting, laser cutting, or waterjet cutting.

Once the required information has been entered, the nesting software begins searching for increasingly efficient layouts. As improved solutions are found, the software updates the nesting arrangement and displays key performance metrics such as:

Total material dimensions required
Material utilization percentage
Estimated waste reduction

Utilization is one of the most important measurements in nesting. It represents how much of the material sheet is converted into usable parts versus wasted scrap. Higher utilization directly reduces material costs and improves overall production efficiency.

Advanced nesting systems use a variety of optimization techniques to maximize utilization, including:

Placing smaller parts inside the cavities of larger parts
Rotating parts to arbitrary angles
Automatically rearranging geometry for tighter packing efficiency

The longer the nesting engine is allowed to process, the more optimized the layout generally becomes. Eventually, however, the improvements reach a point of diminishing returns, and production requirements typically dictate moving forward with the cut.

At that stage, the nesting software exports a finalized CAD file containing the optimized layout. That file can then be imported into a CAM system to generate toolpaths for CNC routers, plasma tables, waterjets, or laser cutting systems.

Nesting is Crucial

It is often the small steps, not the giant leaps, that bring about the most lasting change.