Smart Nesting in Total Print
Nesting is the process of arranging multiple items on the same sheet or roll to use as much material as possible. In real print shops, good nesting is not just about packing shapes tightly – it must also respect cutting, labeling, and delivery. This page explains how to think about nesting in Total Print and how to turn it into a repeatable process.
When to use nesting
Use nesting whenever you have several jobs on the same material, especially small or medium-sized items that leave a lot of unused gaps when printed separately. Typical examples include labels, stickers, small signs, and mixed batches of point-of-sale graphics.
Grouping compatible jobs
Before you start a layout, decide which jobs can share the same roll. In general you want items that share:
- The same material and finish (for example, the same vinyl or banner stock).
- The same print mode or color profile in your RIP.
- Similar due dates, so you do not delay urgent work.
In Total Print, you can import several designs or PDF pages and treat them as a single planning group. The layout preview then shows how they combine on the roll.
Controlling spacing and alignment
Spacing has a direct impact on both waste and finishing effort. Smaller gaps reduce media usage but can make cutting harder; larger gaps make trimming easier but waste more media. Total Print lets you adjust spacing and immediately see the effect on total roll length.
When planning a nested layout, think about rows and columns that your cutting team will understand. Aim for consistent alignment in one direction and use spacing that matches your cutting tools and tolerances.
Example: combining three sticker jobs
- Import three sticker designs that all use the same vinyl.
- Enter the roll width you plan to load and your usual spacing.
- Adjust quantities for each design until you fill the roll width efficiently.
- Check the layout preview to make sure the cutting pattern is clear.
- Save this calculation with a descriptive name so you can repeat it when similar jobs appear.
Building a repeatable nesting workflow
The goal is not to reinvent your nesting rules for every job. Instead, use Total Print to define a few clear patterns that work well in your shop – for example, standard layouts for common sticker sizes or banner sets. Save these scenarios and reuse them as templates. Over time this turns nesting from a one-off puzzle into a stable part of your production process.