This calculator uses a "First Fit, Best Fit" algorithm. Here's how it works:

1. Account for Kerf: First, the calculator adds the blade kerf width to each part length. This ensures the final cut pieces are the correct size.
2. Sort the Parts: It creates a master list of every individual part needed and sorts them in descending order, from longest to shortest.
3. Iterate and Place: The algorithm takes the longest part from the list and looks at all available stock boards. It finds the board where this part will fit while leaving the smallest possible offcut (the "best fit").
4. Update Stock: The part is assigned to that best-fit board, and the board's available length is reduced. The algorithm then takes the next-longest part and repeats the process.
5. Continue Until Done: This continues until all parts have been placed or no suitable stock is left. This method is highly effective because placing the longest parts first leaves more versatile, smaller offcuts for the shorter parts to fit into.

• Cutlist: A list of all the finished-size parts required for a project.
• Stock: The raw material boards or sheets that you will cut your parts from.
• Kerf: The width of the material that is removed by the saw blade during a cut. This is "waste" that must be accounted for.
• Yield: The percentage of the stock material that is used for finished parts. A higher yield means less waste.
• Offcut: The leftover piece of stock material after all required parts have been cut from it. Ideally, these are large enough to be usable for other projects.
• Greedy Algorithm: A type of algorithm that makes the best possible choice at each step, without considering the overall problem. While not always perfect, it's very fast and effective for cutlist optimization.

"An optimizer is a fantastic starting point, but always give the results a sanity check. Sometimes, the computer will suggest a sequence of cuts that is awkward or unsafe to perform on a table saw. Don't be afraid to manually swap a couple of parts between boards if it results in a more practical workflow. The goal is low waste, but safety and practicality come first." - Professional Cabinetmaker

"Always measure your 'stock' boards. A standard 8-foot (96-inch) board from a home center is rarely exactly 96 inches long. It might be 96.5" or 95.75". And don't forget to trim a half-inch off the ends to remove any cracks or checks before you start cutting your parts. Entering accurate stock lengths is crucial for a reliable cutlist."

Example 1: Building a Face Frame
You need four stiles at 30" and four rails at 15". Your stock is 96" boards. The optimizer will likely place two 30" pieces and one 15" piece on the first board `(30+30+15 = 75")`, and the remaining two 30" and three 15" pieces on a second board, minimizing the number of stock boards needed.

Example 2: Mass-Producing Small Parts
Imagine you need 100 parts that are 10" long. The optimizer will quickly show you that you can get 9 parts from each 96" board (`10" * 9 + kerf * 9 ≈ 91.125"`), meaning you'll need 12 stock boards to complete the order (`100 / 9 = 11.11...`). This is much faster than figuring it out by hand.

• Forgetting the Kerf: This is the #1 mistake. If you don't account for the blade's width, every part after the first one will be slightly too short.
• Ignoring Grain Direction: This optimizer works in one dimension (length). It does not account for grain direction, which is critical in woodworking. You must use its output as a guide, but still ensure your rails and stiles are cut with the grain running the correct way.
• Not Planning for Defects: The optimizer assumes your stock boards are perfect. In reality, they have knots and cracks. Always buy a little extra material and be prepared to cut around defects, which may alter the optimal layout.
• Trying to Use Every Last Inch: While minimizing waste is good, creating a tiny, unusable offcut might be less valuable than making a slightly less "optimal" cut that leaves you with a larger, more useful leftover piece for future projects.

• Woodworking: Planning cuts for face frames, cabinet carcasses, tables, and other furniture.
• Metalworking: Optimizing cuts for metal tubing, bar stock, or angle iron.
• Construction: Planning framing cuts for studs and joists to minimize lumber waste.
• Crafting & Hobby Projects: Efficiently cutting materials for any project that requires multiple parts of varying lengths.