Nesting sign letters for LightBurn
LightBurn is where many shops set laser speed and power. NestSigns does the step before: open the letter artwork, pack it onto your sheets and leftover pieces, and download a LightBurn project with every sheet ready to cut.
Start free: 20 runs, no credit cardWhere NestSigns fits
LightBurn has tools to arrange, align and array shapes, and for a few pieces that is quick. For a full set of letters, or a job that has to fit the leftovers on the shelf, shops use NestSigns to do the packing:
- True-shape packing. Letters are placed by their real outlines, and small pieces go inside the holes of O, A, B and D.
- Several sheets at once. A long job is spread over as many sheets as it needs.
- Leftovers. Keep the leftover pieces for each material. The smallest one that fits is used first.
- Numbered parts. Every part is numbered on the sheets and on the original artwork, so sorting after cutting is quick.
The workflow
| Step | Where |
|---|---|
| 1. Open the artwork (.ai, PDF, DXF, SVG or .cdr) and pick the sheet or leftover | NestSigns |
| 2. Nest and check the gaps | NestSigns |
| 3. Download “LightBurn (.zip)”: one .lbrn2 project per sheet | NestSigns |
| 4. Open the project, set speed and power for each layer | LightBurn |
| 5. Frame and cut | Your laser |
The LightBurn file keeps the outlines exactly as drawn, as lines and curves. Each part goes on the LightBurn layer closest to its color in your artwork, so a sheet split by color keeps its colors. Speed and power are left for you to set, because they depend on your laser and material.
If you prefer other files, the same layout downloads as SVG (one file or one per sheet), DXF, PDF or AI.
Spacing for a laser
A laser kerf is small, so the gap can be much tighter than on a router. Many shops use about 0.1 in (2–3 mm) between letters on acrylic so the heat from one cut does not mark the next part. Type the gap you want; NestSigns measures every layout after nesting and shows the smallest gap and edge distance it left.
Sheet size and the laser bed
Set the sheet to your material size, or to the bed size if the sheet is bigger than the bed. Letters too large for the sheet can be left out or divided into pieces labeled A1, A2…
What else it does for letter jobs
- True-shape nesting by the real letter outlines: any angle, 0/180° only, or no rotation.
- Exact spacing. Type the gap or your bit diameter; every layout is checked and shows the smallest gap measured.
- Parts inside letter holes. Small pieces go inside O, A, B and D, and holes stay with their letter.
- Leftovers first. Full sheets and leftover pieces per material, smallest leftovers used first, stock updated when the job is done.
- Oversize letters left out, divided, or divided with a 1 in joining strip, pieces labeled A1, A2…
- Every part numbered on the sheets and on the original artwork in the layout summary PDF.
Cutting the same letters on a router too? See nesting for VCarve and Aspire or the guide how to waste less acrylic.
Questions
Does NestSigns set laser speed and power?
No. NestSigns nests the parts and exports the layout. Speed, power and passes are set in LightBurn, where you already keep them for your laser.
Which LightBurn file does it make?
A .lbrn2 project for each sheet, in a zip, with the outlines on LightBurn color layers. You can also download SVG or DXF and import them into LightBurn.
Is NestSigns made by LightBurn?
No. NestSigns is separate software and is not affiliated with LightBurn Software. LightBurn is a trademark of its owner.
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