OptimalLayout — complete user manual

OptimalLayout is a free online cutting list optimizer for sheet materials such as plywood, MDF, melamine, OSB and chipboard. You do not need to install anything — open the optimizer in your browser and start entering sheets and panels. An account is optional, but signing in lets you save projects to the cloud and reuse them across devices.

If this is your first time, read How it works for a five-step overview, then come back here for the full reference.

The optimizer page has four main areas:

• Header — navigation, sign-in, Pro badge and upgrade button.
• Input panel (left) — stock sheets, panels and kerf.
• Actions — Optimize, Save project, Export PDF.
• Results panel (right) — cutting diagrams, statistics and cut list table.

All measurements use millimetres by default; you can switch to inches at any time using the toggle at the top of the page.

A stock sheet is a full panel of material that you start from — for example a 2440 × 1220 mm sheet of 18 mm plywood. For each sheet you enter:

• Width and height.
• Thickness (informational).
• Optional label (e.g. "Birch ply 18 mm").

Free users can define one sheet type per calculation. Pro users can mix multiple sheet types in a single optimization — useful when combining offcuts with new sheets.

For every part you need, add a row with:

• Width × height (the finished part size).
• Quantity.
• Optional label (e.g. "Side panel", "Shelf").
• Optional grain direction lock — when enabled, the optimizer will not rotate the part 90°.

The free plan allows up to 10 unique panel types per calculation (quantities are unlimited). This covers most cabinets, shelving units and small furniture projects. Pro removes the limit.

Kerf is the width of material removed by the saw blade. OptimalLayout adds the kerf between every cut so finished parts come out at the size you entered, not slightly smaller. The default is 3 mm, typical for a panel saw, but you can change it on every project.

• Panel saw: ~3.0 mm
• Track saw: ~2.4 mm
• Fine cross-cut blade: ~1.5 mm
• Jigsaw / scroll saw: ~1.0 mm

If you are not sure, measure a test cut or check your blade's specifications.

Click Optimize layout to run the nesting engine. It uses a guillotine bin-packing algorithm that tries multiple orderings and rotations, then picks the layout with the highest material yield. Calculations usually complete in well under a second.

If the button is disabled, check the warning underneath — typically you have either exceeded the free panel-type limit or a panel does not fit on any defined sheet.

The results panel shows:

• Cutting diagrams — one image per sheet used, with each part labelled and offcuts shown in grey.
• Statistics — sheets needed, panels placed, waste percentage and total cut length.
• Cut list table — every part with its dimensions and quantity, ready to take to the saw.

Click Export PDF to download the result. You can choose what to include:

• Cutting diagrams only
• Cut list table only
• Both (recommended)

Free exports include a small "Made with OptimalLayout" watermark in the footer. Pro exports are watermark-free and can include your company name and logo for client-ready documents.

You can use OptimalLayout fully anonymously. Creating a free account adds:

• Cloud-saved projects accessible from any device.
• A profile with your name and unit preference.
• A faster path to upgrade to Pro later without re-entering data.

Sign in with email or Google on the sign-in page, then use Save project in the optimizer to store your work. Manage saved projects from My projects in the header.

• Optimize button disabled. A panel is larger than every defined sheet, or you exceeded the 10 panel-type limit on the free plan.
• Parts come out a few millimetres small. Increase the kerf to match your actual blade width.
• PDF does not download. Check that your browser is not blocking pop-ups for this site.
• Project not saving. Make sure you are signed in — saving requires a free account.