What is Nesting?

Nesting is the optimization process of fitting as many parts as possible onto each sheet of material. It is a real-world version of the bin packing problem: fitting shapes into a fixed space with minimal leftover.

The impact. Without nesting optimization, typical material utilization runs around 70%, meaning 30% ends up as scrap. With good nesting software, utilization can reach 85-95%. On a 20-sheet cabinet project using Baltic birch at $133 per sheet, going from 70% to 90% utilization could save 4 to 6 sheets ($532 to $798).

Two types of nesting. Rectangular nesting handles standard panel cutting (plywood, MDF, glass) where all parts are rectangles and cuts are straight. True-shape nesting handles irregular parts, which is common in sheet metal and textile manufacturing.

Constraints in woodworking. Nesting algorithms consider piece dimensions, kerf width, grain direction, edge banding, and whether parts can be rotated 90 degrees. Grain-locked pieces cannot be rotated, which constrains the optimizer and may require additional sheets.

Manual vs. software. Arranging pieces by hand on paper or the material itself works for simple projects but breaks down beyond 15-20 pieces. Software tests thousands of arrangements in seconds to find layouts that use fewer sheets than any human could achieve manually. SmartCutList runs nesting optimization in your browser, handling kerf, grain, and rotation constraints automatically.