How to Reduce Sheet Metal Scrap with CNC Laser Nesting Software

Why Sheet Metal Scrap Matters

For sheet metal fabricators, material is one of the largest costs of production. Even small improvements in material utilization can translate into meaningful savings when multiplied across hundreds or thousands of sheets processed each year.

Every unused area of a sheet represents material that was purchased but did not become a finished part. Some scrap is unavoidable, but the goal is to consistently make better use of the material available.

Better material utilization can help manufacturers:

• Reduce material cost per part
• Produce more parts from the same amount of material
• Reduce the number of sheets required for production
• Generate fewer unusable remnants
• Make better use of existing inventory
• Reduce scrap handling and disposal

What Is CNC Laser Nesting?

CNC laser nesting is the process of arranging parts on sheet material before those parts are cut on a CNC laser. Instead of manually positioning every part, nesting software evaluates the available geometry and determines how parts can be arranged within the usable area of the sheet.

The objective is typically to maximize material utilization while creating a layout that can be cut efficiently and reliably.

A production nest may need to account for:

• Large and small parts
• Irregular part geometry
• Different quantities
• Part rotation restrictions
• Grain-direction requirements
• Different materials and thicknesses
• Production priorities
• Remnant sheets
• Machine-specific cutting requirements

How Nesting Software Reduces Sheet Metal Waste

1. Improving Part Placement

One of the most direct ways nesting software reduces waste is by finding better arrangements for parts. Small changes in orientation or placement can create enough space for additional parts that might otherwise require another sheet.

This becomes particularly important with irregular geometry. Compatible shapes can often be rotated or positioned together in ways that are difficult to recognize manually.

2. Using True Shape Nesting

True shape nesting considers the actual geometry of parts rather than treating every component as a simple rectangular boundary. Curved, angled, and irregular components can therefore use areas of a sheet that might otherwise remain empty.

3. Combining Different Parts on the Same Sheet

Production requirements do not always arrive in combinations that naturally fill an entire sheet. Nesting software can combine compatible parts from different jobs or assemblies onto the same sheet when production requirements allow it.

This can be particularly valuable in high-mix manufacturing environments where many different components are produced in relatively small quantities.

4. Making Better Use of Remnants

A partially used sheet does not necessarily need to become scrap. Usable material remaining after a cutting operation can potentially be saved as a remnant and used for future production.

The challenge is keeping that material organized and making it practical for programmers to reuse. An effective nesting workflow can help manufacturers incorporate available remnants into future nests instead of automatically starting with a new full sheet.

5. Evaluating More Nesting Possibilities

A programmer manually arranging parts may find a good solution. Software can evaluate many potential arrangements in the time it would take a person to create only a few.

This becomes especially valuable when working with large part lists, irregular geometry, multiple sheet sizes, or changing production requirements.

Material Utilization Is Only Part of the Equation

The nest with the highest theoretical material utilization is not always the best nest for production. A layout must also be practical to cut.

Cutting sequences, heat concentration, part movement, lead-ins, common-line opportunities, machine capabilities, and unloading requirements can all influence whether a nest performs well on the shop floor.

Standardize Nesting Across Multiple CNC Machines

Material optimization can become more difficult when a fabrication shop operates equipment from multiple manufacturers.

If every machine requires a separate programming environment, nesting strategies, part data, and workflows can become fragmented. A machine-independent CAD/CAM and nesting environment can help manufacturers standardize programming across equipment.

Instead of optimizing material separately within isolated machine-specific software systems, programmers can work from a more consistent production workflow.

Measure Material Utilization Over Time

Improving nesting should not be treated as a one-time project. Manufacturers should monitor how effectively material is being used and look for patterns over time.

Useful questions include:

• What percentage of each sheet becomes finished parts?
• Which materials or thicknesses generate the most scrap?
• How much usable remnant material is being created?
• How frequently are remnants reused?
• Are programmers consistently achieving similar results?
• Are certain jobs particularly difficult to nest efficiently?
• Could different sheet sizes improve utilization?

How Much Can Better Nesting Save?

The financial impact depends on material volume, material cost, current utilization, part geometry, and the amount of improvement that can realistically be achieved.

The basic principle is straightforward: the more material a manufacturer processes, the more valuable even small improvements in utilization become.

Reducing Scrap Starts Before the Laser Begins Cutting

Once the laser starts cutting, many of the decisions affecting material utilization have already been made.

Part selection, quantities, sheet size, orientation, spacing, remnant selection, and nest layout all influence how efficiently material will be used.

Fabricators looking to reduce scrap should evaluate not only the performance of their cutting machines but also the software and workflows determining what those machines cut.

CNC Laser Nesting with Striker Systems

Striker Systems develops CAD/CAM and nesting software specifically for sheet metal fabrication.

SS-NEST provides automatic true shape nesting designed to help manufacturers efficiently arrange parts and improve sheet utilization.

When combined with Striker Systems CAD/CAM solutions, manufacturers can create a connected workflow from part programming and nesting through CNC production.

For shops operating equipment from multiple manufacturers, Striker's machine-independent approach can also provide a common programming environment rather than requiring the entire production workflow to revolve around a single machine brand.