Adam Ball, Commercial Director at Lantek, looks at use of the latest software to reduce material waste in sheet metal fabrication.
“Nesting is a well-established practice in sheet metal fabrication. It involves the practice of arranging multiple parts to be cut from a single sheet of material in order to minimise waste and maximise material utilisation. This is normally achieved by placing parts as close together as possible, sometimes even sharing cut lines, to reduce scrap and save costs. However, effective nesting is about more than just squeezing the most out of each sheet as how parts are arranged directly influences production efficiency, inventory levels and delivery timelines.
A nesting strategy that focuses solely on minimising material waste may seem ideal at first glance, but in practice, it can create challenges, including the overproduction of unused parts, storage issues, or even disruptions to the production flow.
Machine shops typically approach this trade-off differently. Some focus on minimising scrap at all costs, which often leads to leftover material that is difficult to reuse. Others choose to cut only what is needed for the current order, increasing overall waste. Some shops fill the nesting layout with parts from future jobs, improving material yield but increasing work-in-progress (WIP) and inventory complexity.
So how do you strike a balance between material optimisation and operational efficiency? The answer isn’t a single solution, but it involves adapting the nesting strategy to the workshop’s actual workload and priorities. This requires the latest advanced software that enables data-driven decisions and real-time adjustments without compromising profitability or delivery performance.
Nesting strategies
Decisions about nesting go beyond material usage, as they affect overall shop performance and long-term profitability. Some of the most common approaches include:
Order-driven nesting
With order-driven nesting, only the parts needed for a specific job are cut. This prevents unnecessary inventory build-up but may result in higher scrap rates if the layout does not fully utilise the sheet.
Nesting with reusable remnants
Nesting with reusable remnants involves maximising sheet usage while generating offcuts that can be reused. For this to work, a system must be in place to track, store and manage those remnants effectively.
Nesting with filler parts
In this process, additional parts from upcoming orders are inserted to make the most of available space. While this boosts material yield, it can also lead to excess inventory and more complex planning if those parts are not needed immediately.
Nesting to optimise shopfloor efficiency
When nesting is carried out to optimise shopfloor efficiency, parts are grouped on each sheet based on multiple criteria, with the goal to streamline downstream production processes after cutting.
Each strategy has trade-offs – and the right choice depends on multiple variables—such as customer demand, available storage and how efficiently the workshop handles work in progress.
Adapting a nesting strategy to changing priorities is only possible with the right digital tools. Advanced nesting software offers visibility and control that manual processes can’t match. There are many advantages of this type of software.
Real-time demand visibility
Nesting software integrated with ERP or MES systems provide a clear picture of ongoing orders and future demand. This insight helps determine whether it is best to add filler parts, hold off for a larger batch, or use a remnant from storage—reducing waste and aligning production with actual needs.
Efficient remnant management
It remains a fact that even the best optimised nesting can leave behind usable offcuts. Without proper tracking, these remnants pile up and become waste. The latest advanced software systems, such as Lantek Expert Cut, can catalogue and retrieve remnants in real time, helping production engineers to use them in future nests instead of starting from scratch.
Scenario simulation
Being able to simulate different nesting options before production begins is critical. Advanced software allows an engineer to test layouts that balance material savings with delivery deadlines and machine availability—enabling smarter decisions and fewer compromises.
Once a nesting strategy is agreed, implementing the right software is essential. Effective software integrates with the plant floor to ensure good levels communication, avoidance of manual errors and ensure that production is aligned with planning. This helps to minimise downtime and reduce any errors.
Balancing material, inventory and delivery deadlines
Nesting should not be seen only as a way to reduce material waste. It can have a positive impact across production capacity, warehouse operations and delivery performance.
Machine shops are advised to take a flexible approach to ensure that nesting strategies are adjustable and based on order volume, inventory status and delivery requirements. In addition, effective workflow optimisation should ensure that nesting choices do not create new problems downstream, such as storage overload or production bottlenecks.
Sheet metal fabricators work in a demanding environment and the ability to adjust and execute nesting strategies with precision can make the difference between a profitable shop and one that is constantly reacting to inefficiencies. There is no one-size-fits-all formula—but there is value in staying agile, informed and ready to optimise every sheet, every time.”
Lantek is a leading provider of software solutions tailored for the sheet metal and fabrication industries. Its software systems are designed to manage the entire production process, from initial design through to final assembly. By integrating various functions into a single platform, Lantek enables manufacturers to streamline operations and improve efficiency.
