AutoPanelSizer – optimized cutting layouts for panel-sizing saws

The AutoPanelSizer ­software determines optimized cutting layouts for the ­production of rectangular parts from rectangular raw material and minimizes waste, production times and manufacturing costs. ­AutoPanelSizer generates layouts that can be produced with so-called guillotine cuts, i.e. straight end-to-end cuts. In case of ­interlinked plants, the maximum number of cutting stages is taken into account. ­This makes the software suitable for common cutting technologies applied in the machining of wood and also in the glass, metal and plastics processing industries.

Cutting layouts in seconds

AutoPanelSizer can compute layouts with up to three cutting stages plus head cuts on the first stage (see examples). On the third cutting stage, it is possible to only recut individual parts or to separate multiple parts. The software is able to comply with miscellaneous constraints ­given by machine or material properties.

Available remnants and various sizes of raw sheets can be included in the ­optimization. The computation of a typical ­cutting layout takes from only a few seconds to just a few minutes. When using multiple processor cores (by bundling of licenses), the runtime can be further reduced.

Reduced production costs – increased yield

In the optimization process, the software considers both production times and ­manufacturing costs. It can weigh time-­consuming processes, such as head cuts or the storage of remnants, against a more efficient material utilization. By ­combining identical cutting plans into ­packages, ­simultaneous cuts are feasible thereby reducing production time. ­AutoPanelSizer offers various possibilities to control the generation of such package cuts. Tensions in the material can lead to bent cut edges. To prevent this, AutoPanelSizer can insert stress release cuts, which improve the cut quality.

Furthermore, each part to be produced may be assigned to a part group. This allows for destacking restrictions as well as ­requests regarding a production sequence to be taken into account. In connection with part groups, the optimization can also be carried out across different material types.

Cutting layout with optional parts plus head cut.
© Fraunhofer SCAI
For this cutting layout AutoPanelSizer uses optional parts (dark blue) and three cutting stages plus head cut (main plan in orange).

Anticipatory planning by optional overproduction

In AutoPanelSizer, parts may be declared as required (compulsory) or optional. The former have to be placed on the cutting layouts, the latter are only placed if they fit well and improve the yield. For example, parts that are needed the next day can be declared as required, while parts that are needed later can be declared as optional. This anticipatory production improves the efficiency of the cutting layouts and reduces the overall material consumption.


Integration into existing software

AutoPanelSizer 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, AutoPanelSizer 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.

AutoPanelSizer 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.

Based on the latest research results, Fraunhofer SCAI constantly improves and enhances AutoPanelSizer. AutoPanelSizer benefits from the expertise of the institute in optimization.

Cutting layout with destacking restrictions
© Fraunhofer SCAI
AutoPanelSizer computes this cutting layout in 0.3 seconds. It has been taken into account that only 3 destacking stations are available. Parts with the same color must be destacked together.



  • Consideration of production times and manufacturing costs
  • Balancing time-consuming processes against yield improvement
  • Optimization across multiple materials
  • Adjustable runtime and optimization quality
  • Multithreaded computation


  • Multiple sizes of raw sheets
  • Individual availability
  • Marking as remnants
  • Consideration of grain


  • Required and optional demand
  • Consideration of grain
  • Part groups
    • for specifying a production sequence
    • to model destacking restrictions

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  • Generation of guillotine cutting layouts
  • Limitation on the number of cutting stages
  • Minimum and maximum lengths of cuts and saw feeds
    • for strips, parts, identical strips and end sections
    • for mapping restrictions caused by machine widths, transport devices, suction cups, grippers, pressure beams, etc.
  • Setting the feed direction
  • Horizontal and vertical kerf
  • Trimming at the sheet edges
    • individually adjustable for each side
    • Trims for head cuts and recuts

Head cuts

  • Sizes of the sectional plans
  • Limitation on the number of head sections
  • Weighing against yield


  • Minimum and maximum size
  • Weighing against yield and optional parts
  • Separate settings for head and main plans
  • Preferred use of existing remnants

Third cutting stage / recuts

  • Recuts on individual parts or cutting of multiple parts
  • Maximum and minimum length of offcuts
  • Restriction of recuts to one side of the part (length or width)
  • Weighing against yield

Package cuts

  • Maximum number of sheets
  • Weighing against yield

Stress release cuts

  • Minimum distance between stress release cuts
  • Minimum length of stress release cuts
  • Stress release cut depending on part size


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