What is a cut list optimizer?

A cut list optimizer calculates the most efficient way to cut pieces of required lengths from standard stock bars — using the minimum number of bars and producing the least waste. It solves what engineers call the "1D Cutting Stock Problem."

What algorithm does this calculator use?

This tool uses First-Fit Decreasing (FFD): pieces are sorted from largest to smallest, then each piece is placed into the first bar that has enough remaining space. FFD produces near-optimal results for most fabrication cut lists and runs instantly in your browser — no server required.

What is kerf and why does it matter?

Kerf is the width of material removed by each cut (blade or disc thickness). A 3 mm abrasive disc on 50 pieces costs 150 mm — over two bars of wasted stock. Always enter your actual kerf to get an accurate waste figure.

What is a usable offcut?

A usable offcut is a remnant that is long enough to be used in a future job. You set the minimum length threshold (default: 200 mm). Offcuts meeting this threshold are flagged separately in the plan so they can be returned to stock rather than scrapped.

How is total material weight calculated?

Enable the material weight section, select your material, and enter the unit weight in kg/m (find this on our Metal Weight Calculator). Total weight = bars used × stock length (m) × kg/m. This helps with material procurement and transport planning.

Pipe & Bar Cut List Optimizer

Find the optimal cutting plan for steel pipe, bar, and sections — minimize waste instantly

FFD Algorithm Visual Diagram Metric & Imperial Free Forever

1 Stock Configuration

Preset

Stock Length

Qty Available

pcs

Kerf (Blade Width)

Unit System Metric Imperial

2 Material Weight Optional

3 Cut List

4 Offcut Threshold

Minimum usable remnant length

Remnants ≥ this length are flagged as usable offcuts.

Steel & Fabrication Guides View all articles →

MS Pipe Weight Per Meter → MS Round Bar Weight Per Meter → TMT Bar Weight Per Meter Chart → MS Pipe Fittings Weight → Steel MTO Checklist → Steel BOM Template →

How to Use This Optimizer

The optimizer uses the First-Fit Decreasing (FFD) algorithm: pieces are sorted from largest to smallest and packed into the first available bar with enough space. This produces near-optimal results for most fabrication cut lists instantly, with no server or installation required.

Frequently Asked Questions

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