Aluminium Cutting Planner
Enter your stock lengths and the parts to cut; you get a separate cutting plan, saw loss and offcut calculation for each profile type.
Cutting plan
Inputs have changed; the plan below is out of date. Recalculate to export it.
Enter the data and press “Calculate cutting plan”.
Calculation rules
- Usable length = stock length − end trim.
- One saw kerf is lost after each part; if the length remaining after the last part is shorter than the kerf, the cut consumes that remainder.
- Bar equation: stock length = end trim + parts + saw loss + offcut.
- Waste rate = (end trim + saw loss + scrap offcut) ÷ stock length used. Usable offcuts are not counted as waste and are shown separately.
- Number of cuts = number of parts − 1, plus 1 if length remains after the last part (a remainder shorter than the kerf is consumed by that cut). No final cut is made on a bar that fits exactly.
- The plan is found by heuristic search. It is described as optimal only when this is proven by a lower bound. If genuinely different plans are found, they are compared by number of bars, loss and offcuts.
- Cost is calculated only from the price per metre you enter: stock length ÷ 1000 × price. Waste cost covers end trim, saw loss and scrap offcuts.
How to use
How is the saw kerf applied?
One saw kerf is lost after each part. If the length remaining after the last part is shorter than the kerf, that cut consumes the remainder. Example: cutting 3 × 1200 mm and 2 × 800 mm parts from 6000 mm stock leaves 800 mm before kerf; with a 4 mm kerf, 5 cuts are made and a 780 mm offcut remains.
What is end trim?
It is the length removed once from the start of each bar to cut off an uneven or damaged end (including the cut). It is also applied to existing offcuts.
What is the difference between a usable offcut and scrap?
If the length left on a bar is longer than the minimum you entered, it counts as a usable offcut; if shorter, as scrap. Only end trim, saw loss and scrap count towards the waste rate; usable offcuts are shown separately.
Is the plan always optimal?
No. The plan is found by heuristic search. When a single stock length is used, a lower bound is calculated; if the plan reaches this bound, it is proven to use the “fewest bars”, and this is stated. Otherwise it is shown as the “best plan found”.
Why does the profile type matter?
Parts are cut only from stock of the same profile type; different profiles are never mixed. You can enter the profile code or your own name for it.
Is the data I enter sent anywhere?
No. The calculation runs in your browser; inputs are stored only in this browser for your next visit.