Cut List Optimizer

Frequently Asked Questions

Is this layout guaranteed to be optimal?

First-Fit Decreasing is a strong heuristic, typically within one board of the true optimum. For large production runs a true optimizer can occasionally shave one more board.

What kerf should I use?

A thin-kerf blade is about 3/32 inch (0.094), a full-kerf table-saw blade about 1/8 inch (0.125). Measure your own kerf on a test cut.

Should I cut the longest parts first in real life too?

Yes - cutting longest pieces first preserves flexibility, because a short piece can come out of a long offcut but not the reverse.

Does this work for sheet goods like plywood?

No. Plywood is a two-dimensional problem. This calculator handles only one-dimensional linear stock like boards and trim.

How do I handle defects in rough lumber?

Add the estimated defect length as extra filler parts, or reduce the usable stock length by a defect allowance per board.

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Estimates for informational purposes only.

Important Disclaimer: Estimates for informational purposes only.

This calculator provides estimates for informational purposes only. Results are based on assumptions and may not reflect actual outcomes. Consult qualified professionals in relevant fields before making important decisions based on these results.

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How It Works

When you have a pile of identical-length stock and a cut list of parts to extract from it, the question is "how many boards do I buy, and how do I cut each one to waste the least?" This is the classic one-dimensional cutting-stock problem. The tool takes the stock length, the saw kerf (the material the blade turns to dust on every cut), and your list of part lengths with quantities, then packs them onto as few boards as possible using the First-Fit Decreasing (FFD) bin-packing algorithm.

The algorithm sorts all required pieces longest-first. Each piece is placed on the first board that still has room for it plus a kerf allowance for every cut after the first on that board. If none fit, a fresh board is started. FFD is not guaranteed to find the mathematical optimum but is typically within one board of perfect for realistic cut lists.

The tool returns the number of boards needed, a cut layout for each one, the leftover offcut per board, total waste, and a yield efficiency percentage.

Use Cases

The cut list optimizer handles any one-dimensional linear material:

Planning how many 8-foot boards to buy for a furniture cut list before going to the lumber yard.

Optimizing trim and molding runs to minimize offcuts and avoid mid-run trips back to the store.

Cutting steel tube, aluminum extrusion, or PVC pipe for metalworking and plumbing projects.

Batch-cutting dowels, tenon stock, and shelf-pin strips to maximize yield from expensive figured or exotic wood.

Verifying that a delivered order of lumber is enough to complete a cut list before starting cuts.

Tips

Get the best results from the optimizer with these practices:

Enter all lengths in the same unit (all inches or all feet) to avoid a 12x or 12x error in placement.

Always add 1-2 inches to the stock length to account for end checks and trim cuts on rough lumber that you would not get from a clean-cut board.

Use your measured kerf, not a guess. Measure by crosscutting a board and butting the two halves back together; the gap is your real kerf.

Always buy at least one board beyond the optimized count. One mis-cut piece will stall the project and a single extra board is cheap insurance.

If grain matching or figure matters for show faces, add extra boards since the algorithm packs by length only and cannot account for appearance.

FAQ

Is this layout guaranteed to be optimal?

First-Fit Decreasing is a strong heuristic, typically within one board of the true optimum for ordinary cut lists. For large production runs a true integer-programming optimizer can occasionally shave one more board.

What kerf should I use?

A thin-kerf blade is about 3/32 inch (0.094), a full-kerf table-saw blade about 1/8 inch (0.125), and a bandsaw much less. Measure your own kerf on a test cut for the most accurate result.

Should I cut the longest parts first in real life too?

Yes - cutting longest pieces first preserves flexibility, because a short piece can come out of a long offcut but not the reverse.

Does this work for sheet goods like plywood?

No. Plywood and other sheet goods are a two-dimensional problem (length and width). This calculator handles only one-dimensional linear stock like boards and trim.

How do I handle defects in rough lumber?

Add the estimated defect length as extra filler parts, or reduce the usable stock length by a defect allowance per board to account for snipe, end checks, and knots.

Cut List Optimizer

Frequently Asked Questions

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