Cut List Optimizer — Minimize Wood & Metal Waste

Cut List Optimizer Guide

The Cut List Optimizer solves the one-dimensional cutting-stock problem: fitting many required lengths onto fixed-length stock with the least waste. Start by measuring three inputs. First, the stock length you buy your linear material in — common examples are 8, 10, 12, or 16 ft boards, 20 ft steel tube, or 6 m extrusion; enter it in feet or meters. Second, the saw kerf, the width of material removed by each cut. A standard circular-saw or table-saw blade removes about 0.125 in (1/8 in, ≈3.2 mm); a thin-kerf blade removes ≈0.09 in, a bandsaw ≈0.025 in, and a metal-cutting abrasive wheel can remove 0.1 in or more. Third, your cut list: every finished piece length plus a quantity, with optional labels (rail, stile, shelf). Enter cut lengths in inches when stock is in feet, or centimeters when stock is in meters. The tool then assigns pieces to as few stock pieces as possible and returns a labeled cutting diagram.

Method: each stock length must hold the sum of its piece lengths plus one kerf per internal cut. Usable length per board = stock length − (cuts on that board − 1) × kerf. The optimizer packs pieces greedily (longest-first) into the fewest boards, then reports stock pieces needed, total waste, kerf waste, and efficiency = used length ÷ purchased length. Worked example: you need ten 30 in shelves and eight 18 in rails from 96 in (8 ft) boards, kerf 0.125 in. One board fits three 30 in pieces (90 in + 2 kerfs = 90.25 in, leaving 5.75 in) — so four boards yield twelve 30 in slots, covering all ten shelves. Remaining capacity plus two extra boards absorb the 18 in rails (five per board: 90 in + 4 kerfs = 90.5 in). Total: roughly six 8 ft boards. Purchased length = 6 × 96 = 576 in; used = 10×30 + 8×18 = 444 in; efficiency ≈ 77%.

Always add stock beyond the optimizer's minimum. Real material has defects — knots, splits, bowed ends, mill-end damage — so buy one extra stick per six to eight, roughly a 10–15% margin, and trim 1/2 to 1 in off factory ends before measuring. The single most common mistake is ignoring kerf: omitting a 1/8 in kerf across twenty cuts loses 2.5 in, enough to leave a final piece short. Enter your actual blade kerf, not a guess. A second mistake is mixing units — keep every cut in the same system as the stock. For structural lumber, grade stamps follow voluntary grading-rule standards, and dimensional lumber is sold at nominal sizes (a '2x4' is actually 1.5 x 3.5 in), so measure the real cross-section. Cut lists optimize length only; they assume defect-free, straight stock and do not account for grain direction or finger-jointing. Verify each board against the diagram before cutting — measure twice, cut once.