Precise Material Nesting with ExactFlat: How to Improve Production Efficiency
1. How ExactFlat Works and What Makes It Unique
2. Key Challenges Solved by ExactFlat
3. Alternatives to ExactFlat: Manual Nesting
4. Is ExactFlat Worth Using
5. Conclusion
Nesting of fabric, leather, or composite materials is often one of the most complex challenges in production. Time loss, high rejection rates, and significant material waste are issues faced by many manufacturers. In this article, we’ll explore how these problems can be solved using modern automatic nesting technologies, specifically the ExactFlat plugin.
How ExactFlat Works and What Makes It Unique
ExactFlat is a specialized plugin for Rhinoceros 3D software that automates the creation of patterns by transforming complex 3D surfaces into accurate 2D layouts. It is used in various industries, including:
- furniture manufacturing;
- automotive interiors;
- apparel and footwear production;
- inflatable structure manufacturing;
- shipbuilding/
The process is simple: you upload a 3D model, and the software generates an optimized 2D pattern template that minimizes material waste while ensuring high precision.
Key Challenges Solved by ExactFlat
ExactFlat is designed to address the following common production issues:
1. Accuracy: Reduces human error, lowering rejection rates by up to 30%.
2. Time: Speeds up the nesting process from hours to minutes—up to 80% time savings.
3. Material waste: Optimizes layout to reduce material waste by 20–30%.
Accuracy and Rejection Rate Issues
Manual nesting accuracy depends heavily on the operator’s skill. ExactFlat uses precise computer algorithms to eliminate this variable. For example, a furniture company reduced its rejection rate by 30% within the first quarter after implementing the software.
Time Consumption
Traditional manual pattern creation on a computer can take hours or even days. ExactFlat reduces this to a matter of minutes. One case: a small car seat cover manufacturer cut its nesting time by up to 80%.
Material Savings
ExactFlat automatically optimizes layout, reducing waste by 20–30%, as reported by existing users.
Alternatives to ExactFlat: Manual Nesting
Manual nesting remains a viable alternative for small businesses or those with limited budgets. However, creating patterns manually on a computer takes significantly more time, requires higher qualifications, and often results in greater material waste due to inaccuracy.
Example: creating one manual pattern for a furniture cover can take around 4 hours. With ExactFlat, this process takes only 10–15 minutes.
To make an informed choice of the most suitable material flattening software, we recommend reading the article “ExactFlat and Alternatives.”
Is ExactFlat Worth Using?
The decision between manual and automated nesting like ExactFlat depends on your specific needs and budget. While the plugin’s price is substantial, it quickly pays off through reduced labor hours, fewer errors, and material savings. Typically, businesses recoup the investment within 4–6 months of usage.
Conclusion
ExactFlat is a powerful tool for companies regularly facing challenges related to precision, production time, and material waste. It supports various material types and adjusts the flattening area based on the material’s properties. Manual nesting is still a valid option but tends to be less efficient and more costly in the long run.
