Tutorial · Sheet nesting
How to fit more names on one laser sheet
WeldWords already nests batches for material savings, but this guide explains what the maker is optimizing and what to check before cutting. It covers real-size nesting, safe gaps, ordering, orientation, multi-sheet overflow, and per-sheet export so every name stays the size it should be.
6 minute read · Free to follow · 2 free batch exports + 1 free single export included
Short answer
You fit more names per sheet by keeping every name at its exact finished size and letting the nesting rotate and reorder pieces into the gaps. WeldWords does that automatically across multiple sheets, shows sheet usage, and exports one true-size file per sheet.
Built into WeldWords
WeldWords packs welded names across real material sheets without shrinking them, keeps safe gaps between pieces, shows overflow sheets, and exports each sheet separately for production.
The tutorial explains what WeldWords is doing for you, plus what to check before you cut.
What you need
- A list of names to cut
- Your material sheet dimensions
- Laser software that imports SVG or DXF
- WeldWords for automatic batch nesting
Step by step
Step 1
Paste the full list of names
Enter every name, one per line. WeldWords welds each one into a single outline as you paste, so by the time you start nesting you are working with the actual cut shapes, not text.
Step 2
Set the sheet to match your material
The default sheet is 299.7 × 500.4 mm (11.8 × 19.7 in), and you can switch between millimetres and inches. Set it to the real cutting area of your bed minus any clamp or honeycomb border so names do not land on a clamp.
Step 3
Keep every name its real size
Each name keeps the finished height or width you set for it. Nesting moves and rotates names to fit; it never shrinks a name to squeeze it in. That is the difference between nesting and cramming.
Step 4
Set a safe gap between names
The default gap is 1.2 mm, enough to stop names from touching and warping together on the cut line. Increase it for thicker material or a wider beam kerf; 2–3 mm is a safe choice for 6 mm acrylic.
Step 5
Run the nesting optimization
Start the nest. WeldWords orders the names, rotates the rectangular footprint of each where it helps, and lays them onto the sheet. A progress indicator shows the work is running, so the page never looks frozen.
Step 6
Watch the sheet fill and overflow
The first sheet fills to the practical maximum and remaining names spill onto additional sheets. You can see exactly how much of each sheet is used and how many sheets you will need before you cut anything.
Step 7
Review and reorder if needed
Names stay selectable, so you can move or remove an entry and re-nest. Removing two large names can drop you from three sheets to two, which is real material saved.
Step 8
Export each sheet separately
Each sheet exports as its own true-millimetre SVG or DXF. That lets you cut one sheet, check it, and adjust power or speed for the next without committing all your material at once.
Step 9
Cut the densest sheet first
The fullest sheet is the one most likely to warp or need airflow tweaks. Cut it first on scrap to dial in settings, then run the remaining sheets with confidence.
Tips that save material and time
- Default sheet is 299.7 × 500.4 mm; switch to inches if you buy imperial stock.
- Keep at least a 1.2 mm gap; widen it for thick acrylic or a wide beam kerf.
- Nesting moves and rotates names but never shrinks them — your size is locked.
- Cut the fullest sheet first to dial in settings on scrap.
- Removing two large names can drop you from three sheets to two.
- Export each sheet separately so you can check one before committing the rest.
Questions people ask
How many names fit on one sheet?
It depends on name size and sheet size, but a typical batch of 80 keychain-sized names fills about three sheets at roughly 60% material use. Larger names or smaller sheets mean fewer per sheet.
Does nesting shrink my names?
No. Nesting only moves and rotates the rectangular footprint of each name to fit; the finished size of every name stays exactly what you set.
What if my names need different sizes?
Set the size per name or per group before nesting. The sheet layout respects each name's individual finished size.
Can I cut the sheets one at a time?
Yes. Each sheet exports as its own file, so you can cut one, check it, and adjust power or speed before running the rest.
Do it now instead of reading about it
Type the word, let it weld, export the production file. Try 2 free batch exports and 1 single export, shared per account and internet connection.
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