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A Nested Interest: What Are The Benefits OF Nesting Software?

A Nested Interest: What Are The Benefits OF Nesting Software?

Faster cutting with good cut quality is just one of the benefits when using nesting software. Amey Save, product application engineer, Hypertherm Asia-Pacific, tells us more.

Nesting is a computer-aided manufacturing application (CAD) application where cut profiles are laid out in the most optimal way to minimise raw material wastage. Nesting software commercially available today also can also be integrated with enterprise resource planning (ERP) and material requirements planning (MRP) software, allowing for even greater flexibility.

Q: What are the benefits of using nesting software, and how do they translate into the shop floor?

Amey Save (AS):Nesting software comes with unique and smart nesting algorithms that optimise the cutting sheet with parts. For instance, it can allow the end user to optimise the metal sheet with different cut parts, while keeping sufficient gaps between each part for good cut quality and heat affected zone, so that all parts nested will have good cut dimensions and cut quality.

In general, the benefits can be translated to the shop floor in the following ways:

  • Optimisation of metal sheet with cutting parts:Saving of scrap material results in cost savings for the company.
  • Users can select from a series of tested and verified parameters within the software:This results in faster cutting with good cut quality: Saving time and money on secondary work.
  • Users can apply machine and process defined for lead-ins and lead-outs:This helps to achieve good cut quality and also reduces machine maintenance. Ultimately, this leads to less downtime and higher production.
  • Compatibility with ERP/MRP software:Provides integration with the entire operating process.

Certain software comes with proprietary technologies that have additional benefits. For example, Hypertherm’s nesting software includes True Bevel technology that reduces trial and error in bevel-cutting jobs for mild steel.

Q: Are there any overlooked features that manufacturers can do with nesting technology that turns into improved productivity?

AS: In addition to its core function, advanced nesting software usually comes equipped with certain optional modules, some of which are specific to improving productivity. Some optional modules include:

  • Productivity modules.
  • Enterprise modules.
  • 3D process modules.
  • Machine interface modules.

Our productivity modules contain auto nesting, common line, chain, and bridge cutting functions, which enable users to optimise the nesting layout.

A common problem that many companies encounter is having to keep track of remnant (leftover) metal sheet. With an inventory module, this information will be stored in the database and can be used when required.

Q: Nesting software is not “magic”; physical limitations of the machine have to be taken into account. Is there any common consideration and advice that you’d like to give to users?

AS: I would encourage all users to explore and utilise the optional modules that come with the nesting software. With these optional modules, users have the flexibility to create a customised nesting software (by adding modules as per their requirements) that is suited to their unique needs.

Q: Any common misconceptions about nesting software that you would like to clear up?

AS: We have encountered many nesting CAM software users who think that they can perform plate optimisation manually better than utilising auto nesting. In a way they are right, as nesting software cannot be compared with the human brain nesting logic. That said, nesting software is capable of generating layouts in a much shorter time, as opposed to manual nesting by a user, which helps to save time and increase productivity.

Q: At its heart, nesting software is driven by algorithms in order to reduce material wastage. With technology advancing at a breakneck pace, has there been any advancement in that respect, or to nesting software in general?

AS: Definitely, there’s still room for innovation and improvement in nesting software. For instance, nesting software can come with different modes: Auto Nesting, Manual Nesting, and Hybrid nesting which allows auto and manual nesting both can be used by user. This gives users more control over their nesting layout.

Q: Any other thoughts you would like to share with our readers?

AS: In today’s world, having a powerful vehicle is not sufficient. The vehicle needs to come with features that can be adapted to different road conditions, and offer users flexibility and ease of use.

The same applies to cutting machines as well. Having a big cutting machine alone is not enough. It needs to be complemented by powerful nesting CAM software for optimisation of metal sheet, machine space, shop floor, and human resources, in order for users to reap the most benefits and achieve maximum efficiency and productivity.

Carl Zeiss: Sub-Micrometre Accuracy Measurement For Steering Wheel Components

Carl Zeiss: Sub-Micrometre Accuracy Measurement For Steering Wheel Components

Accuracy in the manufacturing of components in the steering wheel system is essential in enabling optimal steering performance. Contributed by Carl Zeiss 

Automotive supplier TRW Automotive manufactures braking, steering and suspension systems, as well as occupant protection systems and vehicle electronics. The company supplies parts for around 250 different vehicle models and more than 40 car makers. Around 1,000 of the company’s 65,000 employees produce steering systems in the Polish cities of Bielsko-Biała and Czechowice-Dziedzice.

Production Quality

Jarosław Muchajer, a quality manager at the company, is responsible at the company’s Bielsko-Biała site in Poland for the one of the most complex and expensive component of a vehicle after the engine: the steering system.

If the measurement results exceed the tolerances of just 0.1 micrometre, production has to stop. This safety measure can quickly result in exorbitant costs. This led the company to look for precise measuring equipment and 24-hour support from the manufacturer.

Looking For A Solution

When the Bielsko-Biała factory opened in 2012, plant managers drew on their own experience when the time came to select the coordinate and surface measuring systems.

They selected a surface measuring instrument from Zeiss, called the Surfcom 5000. Using five lasers on its interferometer, the unit was able to measure with accuracy levels of around 0.31 nanometres on average. The unit also has a ratio of the measuring range to resolution of approximately 42 million to one.

Steering Systems Market

According to a market report by research firm MarketsAndMarkets, the steering market is projected to grow at a CAGR of 6.47 percent from 2016 to 2021, to reach US$42.77 billion by 2021.

The Asia-Oceania region is estimated to lead in the market in terms of growth rate during the forecast period. The increasing demand for automotive comfort and safety is a key driver of the steering market.

The majority of new cars sold today feature Electric Power Steering (EPS).

Asia-Oceania comprises some of the fastest growing economies in the world, including China, India, and Indonesia. The region has the highest vehicle production in the world, due to its sizeable population and increasing disposable income. The growing population, increase in per capita income, and improving standard of living have contributed to the growth of the automotive industry in Asia Pacific.

The key automotive market in this region is China, which produces the highest number of passenger cars in the world. Given that the steering market is directly dependent on vehicle production, Asia-Oceania has emerged as the fastest growing market for steering systems, in terms of value as well as volume.


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