Cut list optimizer· 2 min read
Cut List Step by Step: How to Cut Boards with the Least Waste
A shelving example shows why a good cut list saves a whole board, how to include the saw kerf and how to mix 3 m and 4 m boards.
You need 4 shelves 1,200 mm long and 6 sides 650 mm long. The store sells boards 3 m and 4 m long (about 10 and 13 ft). How many should you buy? Most people guess “three of the long ones” or “four of the short ones” — and both cost more than they need to.
What you need before cutting
- A list of pieces — the length and quantity of each part.
- The stock lengths your store actually has (here 3,000 and 4,000 mm).
- The kerf — a circular or mitre saw blade removes 2–3 mm with every cut (check the blade), a Japanese pull saw under 1 mm. The example uses 3 mm.
- A squaring cut — factory ends are often not square or are damaged, so we trim a few millimetres from every board. The example uses 5 mm.
Three ways to buy it
| Buy | Bought length | Waste |
|---|---|---|
| 4 × 3,000 mm | 12,000 mm | 27.5 % |
| 3 × 4,000 mm | 12,000 mm | 27.5 % |
| 1 × 4,000 + 2 × 3,000 mm | 10,000 mm | 13 % |
Mixing one long and two short boards saves 2 whole metres of wood. The pieces add up to 8,700 mm, so with these lengths you cannot buy less than 10 metres — the calculator proves it by checking every combination.
The cutting plan
- 14,000 mm board: 1,200 + 1,200 + 1,200 mm, offcut 386 mm.
- 23,000 mm board: 650 + 650 + 650 + 650 mm, offcut 383 mm.
- 33,000 mm board: 1,200 + 650 + 650 mm, offcut 486 mm.
The offcuts are measured after the squaring cut and every saw kerf — that is what really stays on your bench.
Why “just line the pieces up” is not enough
By hand, pieces usually go longest first, each into the first board where it fits. That is a sensible start, but with mixed stock lengths it often ends one board over. Our calculator tries several strategies and, for smaller jobs, searches every combination — then it marks the result as the best possible plan.
Cut list optimizerOpen this example in the cut list optimizerWorkshop tips
- Measure a few boards first — they usually come at the stated length or slightly over, but the ends may not be square or clean.
- Cut the longest pieces first; shorter ones still fit into what is left.
- Keep offcuts over 30 cm (1 ft); they always come in handy for trims and spacers.