Know what the saw will actually do: cut counts, a sawing plan, and machine limits
Every plan now shows how many cuts a job needs, how far the blade travels, and per-side trim. Pro adds a step-by-step sawing plan in all three modes — on screen, in the PDF and in Excel — plus a calibration cut. Workshop adds panel-saw stage and rotation limits.
A cutting plan tells you where the parts sit. It never told you what the day at the saw looks like: how many times you set the fence, how far the blade travels, what to cut first. This update answers all three — and turns the plan into an ordered list of stop positions you can work down.
How many cuts, and how far the blade travels
Two numbers now sit in the results header of every job, on every plan, guests included.
- Cuts counts fence settings. Cutting the same measurement across three strips is one setting, so it counts once — because that is one setup at the machine.
- Saw passes appears under it whenever the two differ, and counts every strip crossed separately. That is the number blade wear and per-cut charges follow.
- Cut length is the total distance sawn — metres in mm mode, feet in inch mode. It is the same figure under either counting convention.
Neither number is the “right” one; they answer different questions. How many times do I set the fence? and how many times does the blade go through material? Quoting a job needs both.
On our standard 40-part demo job (2440 × 1220 sheets, 3 mm kerf) the plan comes out at 44 cuts, 61 saw passes and 35.21 m of sawing across 2 sheets at 83.3% yield.
Trim each edge separately
Trim per side replaces the single trim value in 2D: separate left, right, top and bottom inputs. Available on every plan, guests included.
This is not a refinement, it is a correction. A damaged or out-of-square edge needs more than the others, and trimming all four the same does not give you a slightly worse plan — it gives you a wrong one: too little on the bad edge and your first part carries the defect, too much everywhere else and you have paid for material you never had to lose.
In 1D and Wood a bar has two ends, so the Start trim / End trim pair is shown instead.
The sawing plan — now on bars as well as sheets
The Cutting Sequence used to be a 2D feature. It now runs in 2D Panel, 1D Linear and Wood, on the Pro plan.
On a sheet the plan walks the board down stage by stage: one step per fence setting, with the cut direction and the position, so a cross-cut is never asked for before its strip has been ripped off.
On a bar there is no cut tree — the timber is crossed end to end — so the plan is the running offset: after each part the blade drops at that mark, then advances by the kerf. Each bar reads as the calibration skim (if switched on), then the start-trim head cut (if set), then one step after each part, except a last part that finishes flush with the usable end when there is nothing to trim off it.
Every step gives a stop position measured from the head of the bar. That is the point: a number you can set on a stop, instead of adding part lengths and kerfs in your head twenty times down a six-metre length.
Two ways to use it:
- The player now sits directly above the sheet or bar diagrams it steps through, rather than at the top of the results. Controls are ◀ Previous, the step readout, ▶ Next, the new ⏮ Restart, and ▶ Play. Restart pauses playback and takes you back to step 1 — for the second board, or the second run of a job.
- The table below the cut list is the whole plan on one screen: the order, the sheet or bar, the direction or the part, and the position. Click any row and the player jumps to that step, with the row highlighted. It is what gets read before starting, and what gets screenshotted and sent to the saw.
One honest limit: 1D Linear reports positions but no cut length, because linear stock carries no cross-section for the blade to cross. Wood mode does know the section, so it reports a sawn length there. We would rather leave a figure out than invent one.
The calibration cut, on bars too
The calibration cut skims a thin strip off the material before any part is cut. You measure the strip, compare it with what you asked for, and correct the fence or stop by the difference — so the first real part is already accurate, instead of being the one you sacrifice to find out the setup was off. It is a Pro feature.
It now runs in every mode. On a sheet you pick which of the four edges is skimmed. On a bar the skim always comes off the head, and the side picker is hidden — a bar has one head, and offering four edges would be a control the plan could not honour.
It rides on the start trim: the material reserved at the head is start trim plus calibration. With both set, the head is crossed twice — once for the strip you measure, once to take the rest of the trim off — and the sawing plan lists both passes, in that order.
Two controls that describe your machine
Both are 2D, and both are on the Workshop plan.
- Max. cutting stages. A stage is a run of parallel cuts between two turns of the material — which is exactly how panel saws are specified, as 2-, 3- or 4-stage machines. Tell CutOptim what yours allows and the plan respects it. On that same 40-part demo job, capping it at 2 stages brings the job down to 30 cuts and 32.88 m — with the same yield, the same 2 sheets, and all 40 parts still placed. Fewer setups, no material given away.
- Minimise rotation. Prefers layouts that turn fewer parts, but only when that costs no extra sheet. A sheet is money, a rotation is seconds, so yield is never traded for it.
If a limit cannot be met, you still get the plan. The optimizer returns it and warns which boards need extra setups at the saw — a usable plan with a caveat, never an error.
In the PDF and in Excel
- A Sawing plan page in the PDF, on its own page, in all three modes. On a sheet: board, stage, direction, position and cut length. On a bar: bar, the part the cut frees, and the stop position. The counting convention is printed under the title, and a framed strip of key figures — cuts, saw passes, cut length, stages — sits under the table. Pro.
- A Cutting Sequence tab in the Excel workbook, inserted straight after the Cut list, because it is what the operator works from. The totals are repeated at the bottom, so the tab stands alone when it is the only page taken to the saw. Pro.
- Sheet layouts at full size. In 2D, every board is now repeated on its own landscape page at the back of the PDF, drawn as large as the paper allows. Inline in the portrait flow a 2800 × 2070 board printed at roughly 1:16 — fine as a picture, useless to work from. A landscape page gives about three times the area, and keeps the reading part of the document continuous instead of interleaved with full-page artwork.
- The waste list says whether a leftover is worth keeping. It now starts on its own page and carries a Reusable column, Yes or No, with the keepers listed first — and a line under the table stating the rule in your own numbers: in 2D both sides must clear your minimum offcut size (a long thin strip is not useful), in 1D and Wood the leftover length must clear it.
What’s next
Off-cut auto-include and assembly groups are still on the list, along with a dedicated place for the sawing plan in the label and quotation exports.
Have a feature request or hit a bug? Reply to any CutOptim email or use the contact form.