What is nesting in laser cutting? Let me explain it with a simple example.
Let’s say you’re using a laser cutter to make 10 keychains shaped like hearts from a sheet of acrylic.
❌ Without Nesting:
You’ll randomly place the heart shapes on the sheets, with lots of space between them. This will make you use up more material space and waste the leftover bits.
✅ With Nesting:
You carefully arrange the heart shapes close together by rotating and flipping them like a puzzle to fit neatly. So you can fit all 10 hearts in a smaller space, saving material and money. Smart right?
In this article, let’s delve a bit deeper and in detail to know what is nesting in laser cutting, the importance, fundamentals, methods, and considerations. And in the end, definitely, you’ll be aware of nesting like a pro.
What is Nesting in Laser Cutting?
Nesting in laser cutting is the process of arranging the shapes or parts you want to cut in a way that uses the material most efficiently. The term ‘nesting’ is laying out multiple parts on a single sheet, while reducing scrap waste and optimizing production.
In short: 👉 Nesting = Smart arrangement of parts
Another special skill? The nesting tools help discover the shortest distance from the beginning cut of a part to the final cut of another part and through this it allows the machines to cut parts faster.
The surprising part? The term “nesting” and the methods used to arrange parts have been around for almost 100 years—long before machines were computer-controlled. Back in the early 1900s, especially during wartime, it was important to save time and materials. Skilled machinists worked hard to make the most out of limited resources, and nesting became a common solution. Today, machine shops still use nesting for 2D cutting because it helps save both time and money.
Why is Nesting in Laser Cutting Important?
It’s valuable to understand the value of nesting. No matter whether you are placing an order or making parts yourself, knowing how the parts are arranged and cut helps you to make smarter choices regarding the sizes, thickness, and materials.
✔️ It helps you to reduce waste and minimize the utilization of metal sheets.
✔️ Smooths production, reduces the time to setup, and boosts productivity.
✔️ Reduces unnecessary tool travel while minimising wear and tear on tools.
✔️ Allows you to try different design options and help make necessary changes.
✔️ Eliminates guesswork and guarantees accurate positioning of parts, reducing errors.
✔️ Allows you to complete multiple orders and work on projects simultaneously.
✔️ Minimizes the need for raw material extraction and the energy required for processing.
Read to know more about laser cutting machines.
What are the Fundamentals of Nesting?
Let’s break down the basics of nesting in laser cutting and share some easy tips to keep your designs strong and steady!
- Materials
Knowing how each material behaves helps you design smarter and reduce waste or warping. This is because different materials like metal, plastic, wood, and composites each react differently. Also, things like heat, melting points, and thickness can affect the outcome.
- Nesting Software
Effective nesting helps you get the most out of each sheet by fitting parts closely together. Using smart nesting software, you can rotate, flip, and arrange pieces to cut down on wasted space. This means more parts, less scrap, and better value from your materials.
- Structural Integrity
Closely together does not mean tight spaces. There should be sufficient spaces between parts to prevent them from weakening, especially thin or flexible materials.
- Kerf Width
It is the tiny gaps the laser creates as it cuts through the material. To nest parts accurately, these gaps need to be accounted for so pieces don’t overlap or turn out too small. Luckily, most modern software lets you set the kerf width for perfect precision.
- Heat Distribution
Heat from the laser can warp or distort materials, especially during long cuts. To avoid this, spread out your cuts across the sheet instead of focusing on one spot. Mixing large and small parts in your nesting layout helps the material cool and stay flat.
How to Start Nesting?
Now, as you know what is nesting in laser cutting, also know that you can do nesting in two ways.
MANUAL NESTING:
Imagine you are cutting a mix of rectangles and circles for a DIY project. You manually move each shape around, rotating and flipping them to fit closely together on the sheet. It works, but what if you have 100 pieces to arrange? It can take a long time.
Manual nesting saves money—but not your time or patience!
AUTO NESTING:
Now imagine cutting those 100 parts with auto-nesting in laser cutting software. Instead of arranging them one by one, you upload the shape and, with one click, the software arranges all parts in the most space-saving layout—rotating, flipping, and placing them perfectly.
It saves hours of work and reduces material waste too!
What are the Considerations of Nesting in Laser Cutting?
Before submitting your file, make sure it meets the following guidelines:
- File format: • 2D files: .dxf, .dwg, .ai, or .eps • 3D files: .step or .stp
- Cutout & hole requirements: • For laser cutting: Holes and cutouts must be at least 50% of the material thickness • For waterjet cutting: Minimum hole/cutout size is 0.070″ • For CNC routing: Minimum hole/cutout size is 0.125”
- File setup: • Design is created at 1:1 scale (inches or millimeters preferred) • All elements are placed on a single layer • File is clean—no stray points, duplicate lines, empty objects, or text areas • All shapes are closed (no open contours) • Shapes have been properly united/combined/merged • Text has been converted to outlines or paths • If using cut-out/reversed text, be sure it includes bridges or is stencilized
Conclusion
So, what is nesting in laser cutting? Think of it as puzzle of your parts! By fitting all your shapes tightly together on a sheet, nesting helps save material, cut down on waste, and speed up the cutting process. It’s a smart, space-saving move that keeps your project efficient and your budget happy!
If you’re using a fiber laser cutting machine, nesting becomes even more powerful—maximizing the speed and precision these machines are known for.
Want to level up? You can find top-quality cutting machines available now at Cesar CNC—perfect for boosting productivity and getting the most out of every sheet!
