AutoBarSizer – cutting optimization software for linear materials

The software AutoBarSizer generates optimized layouts for the cutting of stock items, namely steel profiles (metal beams) and other bars and rods, into shorter pieces. The generated layouts achieve an extremely high degree of material utilization (yield), i.e. the cutting waste is minimized. Furthermore, various configurable constraints are taken into account. The planner can also use different parameters to balance yield and additional organizational effort caused by the ­reusable remnants produced.

Optimize miter cuts in seconds

When layouts with miter cuts are created, AutoBarSizer also optimizes the ­interleaving (nesting) of the parts. For this it is sometimes useful to rotate some of the parts. The planner can allow or forbid specific rotations depending on material symmetries and production requirements. AutoBarSizer solves planning questions not only from ­rolling mills and steel traders, but also from the woodworking industry and manufacturers of material strips of all kinds.

The computation of one common sized ­cutting layout is completed in a few seconds to a few minutes at the most.

Benefits of optimized cutting layouts

The computer based optimization of length combinations for cutting bars and rods leads to the best possible avoidance of waste and can thus save ­considerable amounts of expensive ­material. Resources are saved and ­production costs are decreased without ­affecting the quality of product or service. By individual ­assessment of remnant ­usage and remnant production, ­AutoBarSizer allows the user to better manage the stock and avoid unnecessary storage costs for remnants.

© Fraunhofer SCAI
Cutting layout with miter cuts and one reusable remnant (green), computed by AutoBarSizer

Integration into existing software

AutoBarSizer is distributed as a pure geometric optimization engine and can easily be integrated into other applications, such as plant control systems, MES, or ERP systems. For this purpose, AutoBarSizer has an XML interface that can be used via standard input/output, files, or network service. The software runs on all current Microsoft Windows operating systems.

AutoBarSizer addresses two groups of customers,

  • software solution providers who want to integrate an optimization into their application and
  • companies that are willing to program a corresponding connection to their IT systems or ask their IT service provider to do so.

To give you an impression of the performance of our software before you integrate it into your systems, we offer a demo GUI. This simple GUI is not suitable for daily productive use.

© Fraunhofer SCAI
Integration of AutoBarSizer into your existing system. Fraunhofer SCAI supplies only the geometric optimization engine AutoBarSizer (blue box).

Further development

Based on the latest research results, Fraunhofer SCAI constantly improves and enhances ­AutoBarSizer. This is facilitated by the institute´s long-standing experience and wide-ranging ­knowledge of optimization algorithms. Furthermore, Fraunhofer SCAI reacts to the needs of its customers by ­delivering new versions with additional features or by developing custom software involving the service portfolio of AutoBarSizer.

A related project is Cutting of Steel Profiles, where we developed innovative methods for reducing waste metal during the cutting process of profiles in cooperation with a manufacturer of hot-rolled steel profiles.

© Fraunhofer SCAI
AutoBarSizer can also handle large instances. For this instance with 3000 parts (80 different lengths) and 30 different material lengths it finds a solution with a material utilization of over 99%.



  • optimization across multiple materials with distinct properties
  • adjustable runtime and optimization quality
  • key performance indicators support evaluation of computed solutions

Parts and material

  • any number of different parts
  • any number of different stock items
  • optional maximum of stock item lengths used simultaneously
  • individual availability per stock item

Miter cut

  • material-specific profile symmetries that have to be considered when rotating parts for miter cuts
  • minimum lengths for trapezoid waste parts between two mitered parts
  • any miter angle is possible
  • orientation of mitered parts (flat or upright)
  • designated saw side, on which a specific side of each part and stock item must be placed

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  • front and back trim (non-usable sections at the start and end of the stock items)
  • saw blade thickness

Remnants and wastage

  • one- or two-stage evaluation of produced remnants with distinct minimum lengths
  • weigh remnant production against yield
  • preferred usage of existing remnants
  • optional maximum length of produced waste per material


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