Guillotine vs Free Cuts: Which Nesting Mode Should You Use?

When you optimize a cut list, the software needs to know how your cuts work. Not all cutting methods are equal—and using the wrong mode can give you layouts you physically can't cut.

EZNESTING offers two cutting modes: - Guillotine Cuts – Every cut goes edge-to-edge - Free Cuts – Cuts can start and stop anywhere

Understanding the difference helps you get layouts that actually work with your tools.

Guillotine cutting means every cut travels completely across the sheet (or remaining piece) from one edge to the other. Think of a paper guillotine—it slices all the way through.

How it works: 1. Make a cut that divides the sheet into two pieces 2. Each piece can then be cut again, edge-to-edge 3. Continue until all parts are separated

The key rule: You can never make a cut that stops in the middle of a piece. Every cut must reach both edges.

This creates a tree-like cutting pattern where the sheet gets progressively divided into smaller rectangles.

Panel Saws (Vertical & Horizontal) The blade travels in a fixed path. You feed the sheet through, and it cuts all the way across. There's no way to stop mid-sheet.

Table Saws with Sleds When cutting sheet goods on a table saw, you're pushing the entire piece through the blade—edge to edge.

Track Saws / Circular Saws While technically you could stop mid-cut, it's difficult to get clean results. Most users cut edge-to-edge for accuracy.

Beam Saws Industrial saws that process sheet goods automatically—always cutting straight through.

If you use any of these tools, select Guillotine mode in EZNESTING to get layouts you can actually cut.

Free cutting (also called free-form or non-guillotine) means cuts can start and stop anywhere on the sheet. The tool can cut out a piece from the middle without affecting the surrounding material.

How it works: 1. The cutting head moves to the part location 2. Cuts around the perimeter of the piece 3. Moves to the next part—anywhere on the sheet

Parts don't need to be arranged in the "nested rectangle" pattern that guillotine cutting requires. They just need to fit.

This typically results in higher material utilization because the optimizer has more freedom in part placement.

CNC Routers The spindle moves in X and Y axes, cutting parts from anywhere on the sheet. Most common tool for free-form nesting.

Laser Cutters The laser head can start and stop cuts anywhere. Perfect for free-form layouts.

Plasma Cutters Like lasers, plasma can cut from any point on the sheet.

Waterjet Cutters Full X-Y movement allows free-form cutting of any material.

Handheld Jigsaws (for rough work) You can plunge cut and navigate around parts, though precision is limited.

If you use CNC or similar equipment, Free Cuts mode will give you better material utilization.

Rule of thumb: If your blade goes all the way through, use Guillotine. If your tool can cut from any point, use Free Cuts.

Choose Guillotine Cuts if: - You use a panel saw, table saw, or track saw - You don't have CNC equipment - You want simple, sequential cuts - You're cutting by hand with power tools

Choose Free Cuts if: - You have a CNC router, laser, or plasma cutter - Maximum material efficiency is critical - You're generating toolpaths for automated equipment - You're okay with more complex cut sequences

Not sure? Start with Guillotine. The layouts work with ANY cutting method—they're just more restrictive. You can always switch to Free Cuts later if your tools support it.

Switching between modes is simple:

1. Open your project in EZNESTING
2. Look for the Cut Mode option in settings
3. Select Guillotine or Free Cuts
4. Re-optimize your layout

The optimizer will recalculate placements based on your selected mode. You'll likely see different utilization percentages—Free Cuts typically scores higher, but both produce valid, usable layouts.

Pro tip: If you're unsure which mode to use, run your cut list both ways and compare the results. Sometimes the difference is minimal; other times Free Cuts can save you a full sheet.

The difference depends on your parts. Here's what we typically see:

Small, varied parts: Free Cuts can improve utilization by 5-10%. The optimizer fills gaps that guillotine patterns can't reach.

Large, similar parts: Minimal difference (1-3%). Big rectangles pack efficiently either way.

Odd shapes and sizes: Free Cuts shines here. Mixed dimensions benefit most from flexible placement.

Real example: A cabinet project with 47 parts showed 89% utilization with Guillotine and 94% with Free Cuts—saving nearly half a sheet of plywood.

That said, Guillotine layouts are often faster to cut manually. The time saved may offset the extra material cost.

There's no universally "better" option—just the right choice for your tools and workflow.

Panel saw or table saw? Use Guillotine Cuts.

CNC router or laser? Use Free Cuts.

Both? Try both modes and see what works best for each project.

The goal is optimized layouts you can actually cut. Select the mode that matches how you work, and let EZNESTING handle the math.