True-shape nesting
True-shape nesting is nesting that places each part by its real outline, not by a rectangle around it, so parts can sit in the curves and holes of other parts.
Box nesting vs true-shape nesting
Simple nesting treats every part as its bounding box, the smallest rectangle that holds it. That is fast, but letters waste a lot of room inside their boxes: an A, a C or a Y leaves large empty corners.
| Box nesting | True-shape nesting | |
|---|---|---|
| Part is placed as | its bounding rectangle | its real outline |
| Small parts in counters (inside an O, A, B) | no | yes |
| Letters tucked into each other's curves | no | yes |
| Rotation | 0/90° mostly | any angle, if allowed |
| Speed | very fast | slower; the search is harder |
How much it saves depends on the job. Mixed letter sizes with many small parts gain the most; a job of equal rectangles gains almost nothing. The gap between parts still has to match the router bit or laser kerf, so the spacing is set and checked either way.
What you control
- Rotation. Any angle packs best. 0/180° only or no rotation keeps grain or brushed finish in one direction, with less saving.
- Part spacing. Usually the bit diameter plus a small clearance. For example, a 1/4 in bit with 0.05 in clearance gives 0.30 in (typical).
- Edge margin. Space kept free at the sheet edge, for example 0.1 in.
How NestSigns handles it
NestSigns nests by the real outlines of your letters, keeps holes with their letter, puts small parts into counters, and measures the smallest gap on every sheet so you can see the spacing is right.
Related: Nesting · Kerf · Channel letter nesting · All glossary terms
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