Nesting is the process of arranging cut profiles within flat raw material, such as sheet metal, in order to maximize material utilization during the cutting process. This procedure is usually carried out prior to cutting. In the past, most operators in India performed manual nesting, but with the advent of nesting software, automatic nesting became a more attractive alternative. Compared to manual nesting, automatic nesting lays out profiles more efficiently and in a shorter time, thereby making it an increasingly popular option amongst operators.

Nesting software lay out profiles in a manner that reduces wastage

Nesting software, in general, have a number of basic features, such as compatibility with computer-aided design (CAD) programs and computer-numeric controls (CNC). It is common for companies to first design parts using CAD tools, and then transfer the profiles to a nesting software. Because of this requirement, nesting programs are usually configured to import and convert CAD file formats. Some can even automatically correct errors in the files, which would otherwise cause problems during the cutting process. Another typical software feature is an ability to communicate efficiently with a computer-numeric controller (CNC). The process of automated cutting is managed by the CNC, based on a set of instructions from the nesting software. Therefore, nesting tools are required to produce data that is transferable to and readable by a CNC.

The two program features mentioned above are the two primary tasks that a nesting tool can carry out. However, user expectations in India have risen, and customers now look for more value-added functions when selecting such a program. Here are four such features that have been incorporated in some of the latest nesting software on the market.

Increased Productivity

In India, where competition is stiff, a high level of productivity is very important and companies value nesting software that can help increase efficiency. Certain programs position parts on the sheet material in a way that minimises cutting time and improves material optimisation by connecting two or more profiles to form a single cutting path, while eliminating the material separation. This productivity approach is called Common Line Cutting. Any two parts with a straight edge are arranged so they can be cut with a common line.

Also, Chain Cutting links may be created between a variety of single or Common Line profiles, where profiles are joined by a cut path. With a continuous path connecting multiple parts, production time is reduced because the cutting torch makes fewer pierces.

Besides increased efficiency, these continuous cutting functions help companies reduce consumable costs. Without a continuous path, the torch has to pierce the material each time a new part is to be cut. This shortens consumable lifespan significantly since every pierce uses a small amount of the consumable's life. However, by using nesting software that are able to join cut profiles with a single path, the cutting torch makes fewer pierces in order to complete the cutting sequence. With reduced pierce cycles, consumable life is extended and production costs are reduced.

Chain cutting creates a continuous cutting path so that time is saved and consumable life is extended.

Material Optimisation

Keeping production costs low is always a priority, and one of the ways Indian companies can achieve this is by maximizing the use of their materials. Today, advanced nesting tools can automatically develop a layout of selected parts on the sheet, automatically applying optimal part spacing and orientation, in order to maximize the plate utilization. This applies for profiles of both regular and irregular shapes. For square or rectangular parts, other specific functions are available that use advanced column-building logic to achieve efficient nest utilization. In addition, some nesting software are able to consider the actual shape of profiles in order to nest parts beside each other, and within open spaces inside parts. With these features, material utilization is improved and scrap is greatly reduced.

Furthermore, besides making full use of the material in a single session, some of the latest nesting software also allows operators to create custom remnants and add these to the plate list for immediate or future nesting. This reduces wastage because any leftover material can be re-used. With nesting software that features such material optimisation functions, companies will be able to utilize materials more fully.

Custom remnants can be used for future nesting.

One Software for Multiple Cutting Systems

In India, the two most widely-used cutting technologies are oxyfuel and plasma. Within a single factory, both cutting technologies are often employed based on the operator's needs in terms of cut material thickness, because oxyfuel and plasma feature strengths within different cutting ranges. Therefore, a nesting software that can be used for multiple cutting technologies is handy because employees need only to familiarize themselves with a single program. By adopting such software, companies not only increase production efficiency, but can also save on time and resources that would otherwise have been spent on software training. For this reason, operators prefer software solutions that incorporate specific features for plasma and oxyfuel cutting.

Integration

Industry-leading businesses strive to achieve optimum cut quality in order to avoid spending time and money on secondary operations. Where nesting is concerned, efficient communication between nesting software and the other components of a cutting table, such as the power supply, torch height control and CNC, can help to significantly facilitate the production of high cut quality. This is because nesting software that are part of an integrated system can incorporate significant cut process intelligence, which is equivalent to an experienced cutting machine operator.

So, such solutions produce optimised cut quality through automatic job set-up, and aid smooth communication between the various cutting components. Minimal operator intervention is required throughout the process. This attracts companies to source for nesting programs that are part of an integrated cutting system, which are usually available from companies that produce all the key components of a cutting table.

Conclusion

Increasingly, companies look for nesting software that helps save time and cost by increasing productivity, optimising material utilization, compatibility with multiple cutting systems/processes, and cutting table integration that reduces the need for skilled operator involvement. All of these production needs have played an important part in the development of present-day nesting software, and one such example is Hypertherm's nesting software, TurboNest.

Consumer demands are always changing, and nesting software developers will no doubt continue to adapt to accommodate varying requests by offering greater advancements and benefits that will better serve the needs of the industry.

(For 40 years, Hypertherm has been a pioneer in advanced high temperature metal cutting technologies. Setting the standard for cut quality and weldability, the company produces a wide range of automated and manually operated laser and plasma cutting systems. Almost three years ago Hypertherm acquired MTC Software, a nesting software company that is now fully incorporated to the Hypertherm organization. Nesting software products include NestMaster, TurboNest, and ProNest)