Where Nesting is Headed

8/3/2015 Where Nesting is Headed

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Where Nesting is HeadedPrint

DetailsCreated: 20150726

By Ed Huntress, Editor

Writing a roundup of nesting programs is like herding cats: They may look a lot alike, but eachone has a mind of its own. Still, as we questioned the experts at a variety of companies thatproduce nesting software, both machine OEMs who offer it as support software for theirmachines, and independent software companies for whom it’s a major product, it became clearthat there are two general goals, or directions, in which they’re developing their nestingofferings. One is toward improving the quality of nests themselves. Bystronic’s cloudbasedByOptimizer, which we wrote about last month is an extreme example.

The other set of goals could be called improved “integration.” This overused term has a fairlydefined meaning in this case, referring primarily to streamlining the connection to CADprograms at the input end, and to controlling the machine tool at the output end, connecting toCAM or directly to CNC software.

We don’t want to diminish the value of features within the programs, such as 21/2 axis controlfor cutting bevels, or simplifying postprocessing to more easily run a variety of machines, butthe two basic goals clarify what practically all software producers are striving to accomplish. Inboth cases, a primary objective is to reduce the amount of labor that goes into organizing thework of the cutting machine, speeding the endtoend process of moving as quickly as possiblefrom getting an order to shipping finished parts.

http://www.fsmdirect.com/software/nesting/293-optimizing-in-the-cloud



The companies we talked with all are developing better nesting efficiency, up and downstreamintegration, and features that add versatility or performance to their programs. We selectedcertain ones to make one point or another, because they’re good examples, not because that’sall they do. And every fabricator knows that there are many companies that make nestingsoftware than our representative examples.

Multimachine software companies

“The best way to judge nesting is by how many clicks I need to create a nest,” says Anupam(“Andy”) Chakraborty, VP of Metamation, Inc. Metamation makes many kinds of software forfabricators, and their nesting program runs all kinds and all brands of machines. A key for themis programs that pull together the design, nesting, outputs, and connections with ERP. So theintegration part is a major goal, and Andy’s “how many clicks does it take” characterization isabout as clearly as one can define the desired result. Simplifying and automating the steps leadto faster results.

Closely related is the company’s objective of simplifying the user’s interactions with thesoftware. “Our MetaCAM software is the same CAD/CAM environment for 2D, for 3D, and fornesting,” says Andy. “Whether you’re programming for a punch press, a laser, a waterjet, orwhatever, you’re working with the same program and the same interface. And that helps makethe whole system more stable.”

SigmaTEK is another company that makes a designtofinished part integrated softwaresolution, and their nesting component is capable of driving practically any sheet and platecutting machine. The company’s nesting program, SigmaNEST, is integrated with softwarecomponents that can generate quotes based on known variables such as machine run time,material cost, combined work orders, and so on. “This flexibility allows SigmaNEST users, from



the smallest job shop to large OEMs, to create an efficient shop floor,” says the company.

“Adding our SimTrans (Online Data Transaction Manager) bridges SigmaNEST with MRP/ERP,for a higher level of automation.” When the fronttoback processes are highly automated andquick, they beg for a big idea that explains the big benefit. “JustinTime nesting” is SigmaTEK’sconcept. And the consequence of it, they say, is reductions in the need for metal stock.

Another company that sells nesting software for a wide variety of machine types and brands isHypertherm. They’re in a somewhat different position, because they also make hardware forseveral cutting processes. And so they do a lot of software testing and development on theirown hardware.

Derek Weston, the company’s product marketing manager for CAD/CAM software, tells what isdriving their nesting product development: “We, like most companies, follow the market needs.”Hypertherm makes cutting heads and other components, which their customers – machine toolOEMs – build into their machines. So, says Weston, “We look at what they desire, in terms ofthe machines they want to develop. If every OEM that we talked to said ‘You know, we reallyfeel there's a need for a bevel laser and we need you to support that,’ we would work them todo it. If the market for beveled 2D parts, or for 3D parts, developed into something big, we havethe capability to go with that market.”

Without putting words in their mouths, FAB Shop’s opinion is that Hypertherm is more featureoriented. In recent years, they’ve been bearing down hard on using what they know to makeattractive software products. They know what it takes to cut bevels with a plasma cutter, forexample; they do it already. They know what fabricators want their machines to do; they makethe components that do it. So, in their product descriptions (they offer several levels of nestingsoftware), there is an obvious focus on dealing with one practical problem after another, andHypertherm works on automating those steps in programming and setup. Like all other majorcompanies in the business, however, the bottom line is speeding up the time it takes to set upand run a cutting machine.



OEMs and their software

When we looked at nesting programs offered by the machine tool OEMs, our first thought wasthat they have a much easier job. They only have to work with one brand of machines – theirown.

But that, it turns out, is a doubleedged sword. Many, if not most, fabricators have cuttingmachines from two or more manufacturers. They’re likely to go with a SigmaTEK, Metamation,or other multimachine software company in order to avoid having to train their operators onmultiple brands of software.

For the OEMs, that means they have to steer in two directions. First, if they’re selling, say,lasers and press brakes to the same customer, they need a high level of integration across theirmachine types to make their package attractive. For example, bending allowances, “unfolding”features, and other features needed to make a smooth handoff from cutting to bending.

Second, they have to keep an eye on the thirdparty software that many of their customers wantfor crossbrand flexibility. The OEM has to make that a smooth, bugfree integration at its end.

Without detailing long lists of competitive features, the bird’s eye view of their direction istoward offering features that can keep up with those of the broader software companies, whilemaking it easy to use those other companies’ software.

“I’ve worked on both ends, OEMs and software companies,” says Matt Garbarino, marketingmanager for Cincinnati, Inc. “It’s a fulltime job for the software companies to keep theirprocessors current. For us on the OEM side, we need good relationships with those companiesso we can collaborate on satisfying the customer’s need for smooth integration.”



Cincinnati’s software for fabricators consists of several programs, says Garbarino. Besidesnesting, there is unfolding software, which integrates with CAD software to “unfold” a 3D shape;and scheduler software. As noted about OEMs in general, their nesting offerings tend to worktightly with other software to run the downstream machines in the fabricating process – forthose who make such machines as well as cutting machines.

Amada has several nesting products, and it’s interesting to hear the points they bring up first.Again, it’s very featureoriented and pragmatic, dealing with details of the cutting process. “It’sall a rulesbased environment today, where the nesting system is more dynamic,” says MikeZordan, Amada’s GM for software. For example, when deciding whether to nest a long parthorizontally or vertically onto the sheet, it takes into account the number and spacing of supportslats in the bed. That will determine whether the program needs to incorporate tabs on thatpart.

“If it rotates it at 90 degrees vertically, there’s chance that it’s not going to be supported byslats, which means we would establish a rule that says, “In the final nest, if the part’s X value isless than 12 in., we need to tab that part.”

“If we tab that part,” says Zordan, “are we going to put in two tabs or three tabs, for instance?There are rules for it. It’s a fully dynamic environment that we’re faced with.”

“Then, it’s a rulesbased nesting solution that’s going to nest the geometry to get the bestmaterial utilization. After that, it’s going to look at the intelligent rules that we establish for thatgiven situation and apply that logic to the nest, to generate the code in a very efficient, quickmanner.”

Fierce competition pays off for the user

Nesting software has come a long way, and the basic geometric function of nesting hasbecome such a commodity that there actually are free nesting programs available for downloadon the Web. If you’re cutting a few profile goose decoys out of foamcore on your waterjet cutter



over lunch, they may even do the job for you.

But users of commercial nesting software have benefitted from very fierce competition amongthe software companies as well as the OEMs. If you’re looking ahead to consider where you’llgo with nesting, these comments from the software makers will give you an idea of wherethey’re headed, and what we can expect from them in the days to come. Count on everimproving nests that squeeze every square inch out of a sheet; automated programming ofsuch features as kerf widths and head height; and features that use tables and rules to setmany parameters.

As Andy Chakraborty says, one way to judge it is by how many clicks you need to create a nest– or a finished set of parts.

Metamation

SigmaNEST

Amada America

Cincinnati Inc

https://www.sigmanest.com/en-us/

http://www.amada.com/america/

http://www.e-ci.com/

http://metamation.com/

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Where Nesting is Headed