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At EMI, we fully understand that in a metal fabrication business every inch of material matters. That’s why we make CNC tube and pipe plasma cutting systems that are efficient at working with nesting software: to achieve the highest material yield while reducing setup and processing time.
Whether working with steel, aluminum or stainless, efficient material usage means the difference between profit and loss—especially in high-volume production. Most importantly, for fabrication shops focused on cost control, productivity, and sustainability, mastering the art of nesting is a game-changer.
What is Nesting?
Nesting refers to the strategic placement of multiple part outlines within a raw material sheet in a way that optimizes space usage. In CNC tube plasma cutting, this is done using specialized software that arranges shapes as tightly and efficiently as possible, taking into account kerf width, lead-ins/outs, and material margins.
Rather than manually laying out parts or cutting one shape at a time, nesting allows the machine to cut dozens—or even hundreds—of parts in a single, optimized pass.
Benefits of Proper Nesting on a CNC Tube Cutting Plasma Machine
- Reduced Material Waste
Nesting enables operators to fit more parts onto each sheet of metal. By minimizing the unused space between parts, companies can dramatically reduce scrap rates. Over time, this can lead to significant material cost savings—especially when using expensive alloys or large quantities of stock. Material yield through nesting can vary depending on the dimensions of the parts being cut. Typically, a target of 80%-85% material yield is realistic. - Increased Production Efficiency
Most of the cutting options in a typical fabrication shop include cutting the length of the tube or pipe on a saw. This requires a great deal of setup time which sometimes introduces errors in cut length, resulting to scrappage of material. With proper nesting, however, a CNC tube plasma cutting machine can perform more cuts in less time, reducing idle time between cuts and eliminating unnecessary repositioning. This leads to faster production cycles and higher throughput, which in turn helps shops meet tight deadlines and fulfill large orders more efficiently. - Lower Operational Costs
Optimized nesting reduces the number of sheets needed to complete a job, which cuts down on both material purchasing and handling time. Additionally, the reduced cutting time results in less wear on consumables and decreased energy usage. - Improved Part Consistency
Nesting software ensures that parts are positioned and cut in a repeatable, standardized manner. This improves the overall accuracy and uniformity of parts, which is essential for assemblies requiring tight tolerances. - Flexibility for Complex Jobs
Modern nesting software allows for mixed part types, variable tube/pipe lengths, and different materials to be considered simultaneously. This is especially beneficial for custom or short-run fabrication projects, where maximizing efficiency across diverse jobs is critical - Smart Nesting = Smarter Fabrication
For metal fabrication companies, using CNC Plasma Machine that have strong nesting capabilities doesn’t just save time and materials—it adds a layer of intelligence to the production process. It allows shops to quote jobs more accurately, manage inventory more effectively, and scale operations without increasing waste or labor.
Ready to Put Smart Nesting to Work for Your Business?
The ability to nest parts effectively on a CNC tube plasma cutting machine is one of the most powerful ways a metal fabrication shop can boost profitability and productivity. At EMI, all of our machines offer high-quality nesting options and integrate with industry-leading nesting software.
By investing in the right nesting software and training staff on its proper use, you’ll unlock the full potential of your cutting systems and deliver better results with fewer resources. Contact our friendly team of tube plasma cutting experts! We’re standing by to help your business gain an advantage from smart nesting software and CNC production.
