Profile Cutting Optimizer
Free cutting optimization tool for metal bars and profiles. Minimize material waste with visual cutting plans, remnant tracking, and PDF export.
This tool combines the First Fit Decreasing (FFD) algorithm with an exact bar-filling optimization (subset-sum dynamic programming): each bar is packed with the combination of remaining pieces that maximizes material use, and the better of the two plans is shown. As a result, waste concentrates in the last bar as one large usable remnant instead of being scattered across many bars.
Frequently Asked Questions
What is a cutting optimization calculator?
A cutting optimization calculator minimizes material waste by arranging required pieces onto standard stock lengths using algorithms like First Fit Decreasing (FFD). It generates a visual plan showing which pieces go on which bar.
What is blade kerf and why does it matter?
Blade kerf is the width of material removed by the saw blade during each cut, typically 2-5mm for metal cutting saws. Ignoring kerf leads to pieces that don't fit as planned.
How does the FFD algorithm work?
First Fit Decreasing sorts all pieces from longest to shortest, then places each piece into the first stock bar with enough remaining space. This heuristic typically achieves 85-95% material utilization.
Can I use this for wood or plastic cutting?
Yes! While designed for metal profiles, this optimizer works for any linear material — wood boards, PVC pipes, aluminum extrusions, or any stock cut to length.
How accurate is the cutting plan?
The plan is mathematically optimal for the FFD heuristic. Always verify blade kerf settings match your actual saw, and account for any end-trimming or material defects in practice.