Compare Sheet Sizes Before Buying Acrylic: an Eight-panel DXF Example

Two smaller sheets can use less material than one large sheet, even when every part fits on the large one. This example compares both options for the same eight acrylic panels.

I make NestForge and used it to prepare the layouts. The enclosure design is by Jasen's Customs. The source drawings, prepared projects and finished exports are included, so you can inspect the comparison yourself.

This is a digital layout exercise. I haven't cut or assembled the enclosure.

A computer with a current web browser and the free example pack linked in Step 1. You can recalculate and inspect both layouts in NestForge for free, without an account. Export is free for up to 10 parts on one sheet. Exporting the two-sheet job requires the paid version; its finished files are included in the example pack. No physical materials are needed for this layout comparison.

Download the free example pack. It contains the original design files, two prepared nesting projects, DXF/SVG/PDF results and illustrated instructions. Keep the source credits and license with any copies you share.

Open NestForge, choose Open .nest and load the one-sheet project. You should see eight parts and a 900 x 600 mm sheet. This project runs in the free version without an account.

Use millimeters, Draft effort and seed 42. The project uses 90-degree rotation steps, no mirroring, a 5 mm sheet margin, 3 mm minimum spacing and 0.2 mm kerf. Keep the geometry, quantities and these settings the same when comparing sheet sizes.

Click Nest. Check that all eight parts are placed and the layout checks pass. Repeat with the supplied two-sheet project, which uses two 600 x 400 mm sheets. Both calculations and their on-screen results are free. The pack also includes the finished exports for inspection.

The large sheet is 0.54 square meters. The two smaller sheets total 0.48 square meters. For this example, that is 11.1% less sheet area with every part still placed. Compare the prices of the stock you can actually buy, and whether the offcuts will be useful for another job.

Export a DXF, SVG or PDF cut sheet. For the prepared DXF example, use strict R12 POLYLINE and leave Include sheet outline off. Check dimensions in your cutting software before preparing the cut. Use the original enclosure's build notes for material fit and assembly.

Credits: Case design: Jasen's Customs, FightStickLayoutProject, revision d86b5fbc7fb8b03896b8c41c91b7898a2b663242. Original drawings and adapted examples: CC BY-SA 4.0. Nesting preparation, layouts and guide: Madegrain. Full notices and change record are in the download.