ExactFlat and alternatives: how to choose the best software for material nesting

1. What to consider when choosing nesting software
2. Overview of nesting programs
2.1. ExactFlat
2.2. RhinoNest
2.3. Lectra
2.4. Optitex
2.5. Manual nesting
3. Nesting software comparison
4. Conclusion

Material nesting for fabrics, leather, composites, or other surfaces can significantly affect the profitability of your business.

If you’re in the business of manufacturing furniture, automotive interiors, or garments, you already know how critical it is to choose the right software for pattern making.

In this article, we review popular tools like ExactFlat, RhinoNest, Lectra, and Optitex, and compare them with manual nesting methods.

Choosing the right tool can greatly reduce material waste and save production time. So, how do you pick the best one? Let’s dive in.

What to consider when choosing nesting software

Before choosing a pattern-making program, consider the following factors:

1. What materials do you work with: fabrics, leather, composites
2. What is your production scale — custom or mass production
3. How complex are your shapes and pattern layouts
4. What is the skill level of the team who will use the software
5. What is your budget for purchase and implementation

Now let’s move on to a detailed review of the programs.

Overview of nesting programs

ExactFlat

ExactFlat is a plugin for Rhinoceros 3D, that transforms complex 3D surfaces into accurate 2D patterns.

Pros:

– High nesting accuracy
– Fast processing (up to 80% time savings)
– Optimized material usage
– User-friendly interface

Cons:

– High cost
– Requires staff training

RhinoNest

RhinoNest also works with Rhinoceros, but it’s better suited for simpler tasks.

Pros:

– Easy to use
– More affordable
– Helps reduce material waste
– Integrates seamlessly with Rhino

Cons:

– Less precise with complex 3D geometry
– May require manual editing
– Lower automation than ExactFlat

Lectra

Lectra offers enterprise-level solutions for industrial-scale production.

Pros:

– Powerful CAD/CAM system for full workflow automation
– Excellent accuracy
– Ideal for large-scale operations

Cons:

– Very expensive
– Complex implementation and training process
– Less flexible for small businesses

Optitex

Optitex is commonly used in the textile industry and includes powerful virtual sampling tools.

Pros:

– High accuracy with fabrics
– Up to 30% material savings
– Relatively easy to implement

Cons:

– Less effective for materials like leather or composites

Manual Nesting

Manual methods are still widely used, especially by small workshops.

Pros:

– Minimal upfront investment
– Full control and flexibility

Cons:

– Time-consuming
– High chance of human error
– Inefficient use of material

Nesting Software Comparison

Conclusion

The right choice depends on your business needs and resources. ExactFlat is ideal for precision and automation, RhinoNest suits moderate tasks, Lectra is perfect for large enterprises, Optitex is strong in textile-specific workflows, and manual nesting is still a valid option for small and flexible operations.