One of the biggest factors directly affecting cost in sheet metal fabrication is how parts are arranged on the sheet before cutting. This layout optimization, known as nesting, can significantly reduce material waste when done correctly, delivering both cost and production time advantages.
What Is Nesting?
Nesting is the process of automatically or semi-automatically arranging parts of different geometries on a sheet metal blank to minimize the gaps between them and make maximum use of the sheet. CAD/CAM software analyzes part geometries and calculates the most efficient layout on the sheet.
The Impact of Nesting Optimization on Waste
In an unoptimized layout, unnecessary gaps remain between parts, and a significant portion of the sheet ends up scrapped unused. A good nesting strategy can reduce this waste rate by 10-20%, which represents substantial material savings, especially in high-volume production.
Factors That Affect Nesting Optimization
Diversity of Part Geometry
Processing parts of different shapes and sizes together allows the software to generate more flexible layout options. Reducing waste is more difficult when working with uniform, large parts.
Common Line Cutting
In laser and plasma cutting, common line cutting between adjacent parts saves both material and cutting time. This technique places parts directly next to each other so they're separated by a single cut line.
Sheet Size and Standardization
Stocking sheets of different sizes and selecting the size most suitable for a project improves nesting efficiency. Orders that fall outside standard sheet sizes typically result in higher waste rates.
Order Grouping
Combining small parts from different projects into a single nesting plan optimizes sheet usage and can further reduce the waste rate.
The Role of Nesting Software
Advanced nesting software can analyze hundreds of different part geometries in seconds and automatically suggest an optimal layout. However, it's also important for the production team to evaluate the software's suggested result from a practical standpoint; in some cases, a layout that saves material may carry a risk of heat buildup or part deformation during cutting.
The Cost Impact of Waste Reduction
Since material makes up a significant share of total production cost in sheet metal fabrication, the 10-20% waste reduction achieved through nesting optimization directly translates into overall project savings. It also means less scrap, less recycling, and lower storage costs.
DMK Makina's Approach to Nesting
DMK Makina groups orders from different projects wherever possible and uses advanced nesting software to optimize material usage. This approach delivers cost advantages to customers while reducing the environmental impact of the production process.
Serving manufacturers across the Thrace and Marmara regions, DMK Makina offers competitive pricing through efficient material usage, carefully managing the nesting process on every project.