How to optimize metal cuts: a practical guide
A good cutting plan is more than a list of lengths. It needs a correct inventory count, finished-part requirements, realistic cutting allowances and a final check that nothing is missing.
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Finished parts + cutting allowances + leftover = stock length
What this calculation covers
Start by checking that the stock lengths match what is physically in the workshop. Separate incompatible materials, profiles and sections. Then list each required finished part, set the width lost to the blade and review the generated cut layout.
The plan is a multi-strategy heuristic, not a certified optimal cut plan. Some input problems may remain partially unallocated. Verify all dimensions against the drawing.
A real-number cut list example
For a 6,000 mm bar, a 2,250 mm member, a 1,750 mm member and a 1,200 mm brace total 5,200 mm. If three 3 mm cuts are needed, the nominal remaining material is 791 mm before other allowances.
Length balance: 5200 mm finished + 9 mm kerf + 791 mm leftover = 6000 mm stock.
This illustrative example assumes zero head trim and tail reserve. Always enter your actual machine allowances.
How to prepare a cutting plan
Measure available stock
Count full bars and usable remnants, check each length and group compatible profiles.
Enter the job parts
Use stable part IDs, finished lengths and quantities copied from the drawing.
Set cutting allowances
Add saw kerf, head trim and tail reserve; use the actual machine process as the reference.
Calculate and inspect
Run MetalCut, check that every required part was placed and read the leftover lengths.
Export and independently verify
Save CSV or print a PDF and double-check material, tolerances and machine setup before production.
Enter stock, parts and saw kerf in the free 1D MetalCut calculator.
Common questions
What should I check before cutting?
Check part counts, stock identity, dimensions, kerf, trim allowances, tolerances, fit-up and machine safety.
Can the plan be saved as a PDF?
Yes. Open the main calculator, generate a plan and use Print / PDF to save it using the browser.