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Cut List Optimizer

List the parts you need, set the sheet size, saw kerf and grain, and get cutting diagrams that fit the parts on as few plywood or MDF sheets as possible. See the waste percentage and material cost, then print the diagrams or download a PDF for the shop.

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Sheet stock

Parts

LabelLengthWidthQtyGrainRemove
Fractions work: 23 1/2, 23-1/2 or 23.5. Length runs along the grain.

Cutting diagrams

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How to use the Cut List Optimizer

  1. Set the sheet: pick a common size or type your own, and enter the saw kerf (1/8 in for most table saw blades) and any edge trim for factory edges.
  2. Enter your parts with a label, length, width and quantity. Length is the dimension that follows the wood grain.
  3. Lock the grain on visible parts that must not be rotated, and leave it unticked for hidden parts that can turn 90°.
  4. Choose the layout type: straight through-cuts for a table saw, or nested for a CNC router or track saw.
  5. Press Calculate and review the diagrams, waste % and sheet count, then download the PDF or print it for the shop.

How to cut plywood efficiently

  1. Measure finished part sizes, including any extra for edge banding or trimming to final size.
  2. Decide which parts show. Cabinet sides, doors and drawer fronts look best with the grain running the long way, so lock their grain. Backs, bottoms and stretchers can usually rotate.
  3. Rip first, then crosscut. On a table saw, break each sheet into long strips (the first cuts across the whole sheet in the diagrams), then crosscut strips into parts. Breaking a full sheet into smaller pieces with a circular saw or track saw first makes it safer to handle.
  4. Label parts as you cut using the numbers on the diagram so identical-looking pieces don't get mixed up.
  5. Save the offcuts. The diagram shows where the largest leftover piece will be, often enough for drawer bottoms or jigs.

Common sheet sizes and kerf values

SheetSizeAreaTypical use
Standard plywood, MDF, OSB (US)4 × 8 ft (48 × 96 in)32 sq ftCabinets, furniture, shelving
Baltic birch plywood5 × 5 ft (60 × 60 in)25 sq ftDrawers, jigs, fine furniture
Large-format panels5 × 10 ft (60 × 120 in)50 sq ftCountertops, commercial casework
Project panel2 × 4 ft (24 × 48 in)8 sq ftSmall projects, crafts
Metric board2440 × 1220 mm2.98 m²The metric equivalent of 4 × 8
Saw / bladeApproximate kerf
Full-kerf 10 in table saw blade1/8 in (3.2 mm)
Thin-kerf 10 in blade3/32 in (2.4 mm)
7-1/4 in circular saw bladeabout 1/16 to 3/32 in (1.6–2.4 mm)
Track sawabout 1/16 to 3/32 in (1.6–2.4 mm)
CNC router, 1/4 in bit1/4 in (6.35 mm)

Kerf varies by blade, so check the blade's specification or measure a test cut. To estimate how many sheets you need to cover a floor, wall or roof rather than cut parts, use the Plywood Sheet Calculator; for solid lumber, the Board Foot Calculator.

Frequently asked questions

How does the cut list optimizer work?

It expands your parts list into individual pieces, adds the saw kerf to each piece and then places them on sheets with several packing heuristics (best area fit, best short side fit and others) and five different sort orders. Every combination is tried and the layout with the fewest sheets is kept; ties go to the layout that leaves the biggest usable offcut on the last sheet.

Is this the perfect layout with the least possible waste?

Not always. Finding a guaranteed optimal layout is a very hard math problem (2D bin packing), so all practical cut list tools use heuristics. Running many strategies gets close to the best layout for typical furniture and cabinet projects, but an experienced eye can sometimes squeeze one more part onto a sheet.

What saw kerf should I enter?

Use the thickness of the cut your blade makes. Most full-kerf 10-inch table saw blades cut about 1/8 in (3.2 mm), thin-kerf blades about 3/32 in (2.4 mm), and track saws roughly 1/16 to 3/32 in. If unsure, measure a test cut with calipers. The tool reserves the kerf between every pair of neighboring parts.

What is the difference between the two layout types?

Straight through-cuts (guillotine layout) means every cut runs all the way across the current piece, which is how you cut sheets on a table saw or panel saw: rip strips first, then crosscut them. Nested layouts can place parts in positions that need stopped cuts, which suits a CNC router or a track saw and sometimes saves a little more material.

What does the grain lock do?

When the sheet has grain and a part's Grain box is ticked, that part is always placed with its length running along the sheet's length (the grain direction of standard plywood). Untick it for parts where looks do not matter, such as cabinet backs, stretchers or drawer bottoms, so they can be rotated to fit better.

How is the waste percentage calculated?

Waste % = 1 − (total area of all parts ÷ total area of all sheets used). It includes kerf, edge trim and every offcut, including the unused part of the last sheet, so a project that needs 2.2 sheets shows more waste than one that fills exactly 2. Large offcuts are still useful material for later projects.

Should I add extra for mistakes?

It is common to buy one extra sheet for larger projects, or at least make sure the last sheet has a generous offcut. Factory edges on plywood are often damaged, so many woodworkers enter an edge trim of 1/4 to 1/2 in to cut a fresh straight edge.

Are all the tools on FreeToolCabin tested for quality and accuracy?

Yes! Every tool on our site undergoes automated Q/A testing in real browser environments to ensure high precision, correct output, and zero errors. If you happen to spot a bug or have a suggestion, please contact us at [email protected] and our team will review it right away.

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