Why a cut list optimizer is worth using
The naive approach — buy one board per piece — wastes money and time. Most woodworkers pay 20-40% more than they need to, simply because they don't pack parts efficiently.
This tool does a first-fit-decreasing (FFD) bin packing: it sorts your parts largest-first, then fits each piece onto the first available board where it fits. It is not a true optimal solver (that would take hours), but it's close enough to hand layout for 90% of projects, and much faster.
What this calculator accounts for
- Kerf width — saw blades remove material between cuts. For a 0.125" blade, every cut "costs" 1/8" of board length.
- Rotational flipping — parts can be rotated 90° to fit better. The optimizer tries both orientations.
- Multiple stock boards — add as many boards as you have. The optimizer uses the minimum needed.
- Waste visualization — leftover areas are shown with hatched borders so you can see where to cut scraps for smaller projects later.
What it doesn't do
- Grain direction matching — if your parts need book-matched grain (e.g., for a tabletop), the optimizer doesn't know. You'll need to lay those out by hand.
- Crosscut vs rip optimization — the tool treats cuts as free; real shops have setup time between cuts.
- 3D nesting — this only handles 2D rectangles on flat boards. If you're cutting parts from plywood, use a sheet-good layout instead.
How to use the result
- Read the diagram: each rectangle is a part. The number inside is the part name.
- Mark each cut on your stock board with a pencil and square before sawing.
- Cut the longest parts first. If something goes wrong with a cut, you want to lose the smallest piece possible.
- Save the leftover pieces (the "waste" rectangles) — they often become drawer dividers, jigs, or test cuts.
Common questions
Why does my yield only show 70%?
Real-world yields of 60-80% are normal. Reaching 90%+ requires parts that fit perfectly into the board's dimensions, which rarely happens. Don't chase yield at the expense of workflow — a clean 70% with short cuts is better than a messy 85% with complex layouts.
Can I use this for plywood?
Not directly — plywood sheets are 4'×8' and parts often have grain-direction constraints. We'd need a separate sheet-good optimizer. For now, sketch by hand and use this tool for your solid-wood parts.
What's a good kerf value?
Common kerfs: 10" miter saw ≈ 0.125", standard circular saw ≈ 0.125", track saw ≈ 0.060"–0.080", bandsaw (resawing) ≈ 0.030"–0.060". Check your specific blade's spec sheet for the actual width.