OpenNest/README.md

OpenNest

A Windows desktop application for CNC nesting — imports DXF drawings, arranges parts on material plates, and exports layouts as DXF or G-code for cutting.

OpenNest takes your part drawings, lets you define your sheet (plate) sizes, and arranges the parts to make efficient use of material. The result can be exported as DXF files or post-processed into G-code that your CNC cutting machine understands.

Features

Import & Export

Feature	Description
DXF/DWG Import	Load part drawings from AutoCAD DXF or DWG files via ACadSharp
DXF Export	Export completed nest layouts back to DXF for downstream tools
BOM Import	Batch-import part lists with quantities from Excel spreadsheets
Bend Line Detection	Import bend lines from DXF via pluggable detectors (SolidWorks flat pattern built in)
Built-in Shapes	12 parametric shapes (circles, rectangles, L/T/flange, etc.) for quick parts

Nesting

Feature	Description
Pluggable Engines	Default multi-phase, Vertical Remnant, Horizontal Remnant, plus custom plugin DLLs
Fill Strategies	Linear grid, interlocking pairs, rectangle best-fit, and extents-based tiling
Best-Fit Pair Nesting	NFP-based pair evaluation finds tight interlocking orientations between parts
Gravity Compaction	Polygon-based directional push to close gaps after filling
Part Rotation	Automatic angle sweep to find better fits across allowed orientations
Multi-Plate Support	Manage multiple plates of different sizes and materials in one nest

Plate Operations

Feature	Description
Sheet Cut-Offs	Auto-generated trim cuts with geometry-aware clearance around placed parts
Drawing Splitting	Split oversized parts with straight cuts, weld-gap tabs, or spike-groove joints
Interactive Editing	Zoom, pan, select, clone, rotate, push, and manually arrange parts

CNC Output

Feature	Description
Lead-Ins, Lead-Outs & Tabs	Configurable approach/exit paths and holding tabs with snap placement
Contour & Program Editing	Inline G-code editor with contour reordering and cut-direction reversal
User-Defined Variables	Named G-code variables ($name) emitted as machine variables (#200+) at post time
Post-Processors	Plugin-based G-code generation; Cincinnati CL-707/800/900/940/CLX included

Prerequisites

• Windows 10 or later
• .NET 8 SDK

Getting Started

Build

git clone https://github.com/ajisaacs/OpenNest.git
cd OpenNest
dotnet build OpenNest.sln

Run

dotnet run --project OpenNest/OpenNest.csproj

Or open OpenNest.sln in Visual Studio and run the OpenNest project.

Quick Walkthrough

1. Create a nest — File > New Nest
2. Add drawings — Import DXF files via the CAD Converter (handles bend detection, layer filtering, and color/linetype exclusion) or create built-in shapes
3. Set up a plate — Define the plate size, material, quadrant, and spacing
4. Fill the plate — The nesting engine arranges parts automatically using the active fill strategy
5. Add cut-offs — Optionally add horizontal/vertical cut-off lines to trim unused plate material
6. Export — Save as a .nest file, export to DXF, or post-process to G-code

Command-Line Interface

OpenNest includes a CLI for batch nesting without the GUI — useful for automation, scripting, and CI pipelines.

dotnet run --project OpenNest.Console/OpenNest.Console.csproj -- <input-files> [options]

Import DXF files and nest onto a plate:

# Import a DXF and fill a 60x120 plate
dotnet run --project OpenNest.Console/OpenNest.Console.csproj -- part.dxf --size 60x120

# Import multiple DXFs with mixed-part auto-nesting (experimental)
dotnet run --project OpenNest.Console/OpenNest.Console.csproj -- part1.dxf part2.dxf --size 60x120 --autonest

Work with existing nest files:

# Re-fill an existing nest file
dotnet run --project OpenNest.Console/OpenNest.Console.csproj -- project.zip

# Add a new DXF to an existing nest and auto-nest
dotnet run --project OpenNest.Console/OpenNest.Console.csproj -- project.zip extra-part.dxf --autonest

Options:

Option	Description
--size <WxL>	Plate size (e.g. 60x120). Required for DXF-only mode.
--autonest	Use mixed-part nesting instead of linear fill (experimental)
--drawing <name>	Select which drawing to fill with (default: first)
--quantity <n>	Max parts to place (default: unlimited)
--spacing <value>	Override part spacing
--template <path>	Load plate defaults (thickness, quadrant, material, spacing) from a nest file
--output <path>	Output file path (default: <input>-result.zip)
--keep-parts	Keep existing parts instead of clearing before fill
--check-overlaps	Run overlap detection after fill (exits with code 1 if found)
--engine <name>	Select a registered nesting engine
--post <name>	Post-process the result with the named post-processor plugin
--no-save	Skip saving the output file
--no-log	Skip writing the debug log

Project Structure

OpenNest.sln
├── OpenNest/                   # WinForms desktop application (UI)
├── OpenNest.Core/              # Domain model, geometry, and CNC primitives
├── OpenNest.Engine/            # Nesting algorithms (fill, pack, compact, best-fit)
├── OpenNest.IO/                # File I/O — DXF import/export, nest file format
├── OpenNest.Console/           # Command-line interface for batch nesting
├── OpenNest.Api/               # Programmatic nesting API (NestRunner pipeline)
├── OpenNest.Data/              # Machine configuration and cutting parameters
├── OpenNest.Gpu/               # GPU-accelerated pair evaluation (ILGPU)
├── OpenNest.Training/          # ML training data collection (SQLite + EF Core)
├── OpenNest.Mcp/               # MCP server for AI tool integration
├── OpenNest.Posts.Cincinnati/  # Cincinnati CL-707 laser post-processor plugin
└── OpenNest.Tests/             # Unit tests (xUnit)

Project	What it does
OpenNest	The app you run. WinForms MDI interface with plate viewer, drawing list, CAD converter, and dialogs.
OpenNest.Console	Command-line interface for batch nesting, scripting, and automation.
OpenNest.Core	The building blocks — parts, plates, drawings, geometry, G-code representation, bend lines, cut-offs, and drawing splitting.
OpenNest.Engine	The brains — fill strategies (linear, pairs, rect best-fit, extents), NFP-based pair evaluation, gravity compaction, and a pluggable engine registry.
OpenNest.IO	Reads and writes files — DXF/DWG (via ACadSharp), G-code, the .nest ZIP format, BOM spreadsheets (via ClosedXML), and bend detection from CAD files.
OpenNest.Api	High-level API for running the full nesting pipeline programmatically (import, nest, export).
OpenNest.Data	Machine configuration data layer — stores machine profiles, material/thickness parameters, lead-in/lead-out settings, and cut-off defaults. JSON-based local storage with an IDataProvider interface.
OpenNest.Gpu	GPU-accelerated bitmap overlap detection for best-fit pair evaluation using ILGPU.
OpenNest.Posts.Cincinnati	Post-processor plugin for Cincinnati CL-707/800/900/940/CLX laser cutting machines. Outputs Cincinnati-format G-code with material library, kerf compensation, and pierce logic.
OpenNest.Mcp	MCP (Model Context Protocol) server exposing nesting operations as tools for AI assistants.
OpenNest.Tests	89 test files covering core geometry, fill strategies, splitting, bending, BOM import, post-processing, and the API.

Nesting Engines

OpenNest uses a pluggable engine architecture. The active engine can be selected at runtime.

Engine	Description
Default	Multi-phase strategy: linear fill, pair fill, rect best-fit, then remainder. Balances density and speed.
Vertical Remnant	Optimizes for a clean vertical drop on the right side of the plate.
Horizontal Remnant	Optimizes for a clean horizontal drop on the top of the plate.

Custom engines can be built by subclassing NestEngineBase and registering via NestEngineRegistry or dropping a plugin DLL in the Engines/ directory.

Fill Strategies

Each engine composes from a set of fill strategies:

Strategy	Description
Linear	Grid-based fill with geometry-aware copy distance and 4-config rotation/axis optimization
Pairs	NFP-based interlocking pair evaluation — finds tight-fitting orientations between two parts
Rect Best-Fit	Greedy rectangle bin-packing with horizontal and vertical orientation trials
Extents	Extents-based pair tiling for simple rectangular arrangements

Drawing Splitting

Oversized parts that don't fit on a single plate can be split into smaller pieces:

• Straight Split — Clean cut with no joining features
• Weld-Gap Tabs — Rectangular tab spacers on one side for weld alignment
• Spike-Groove — Interlocking V-shaped spike and groove pairs for self-aligning joints

The split system supports fit-to-plate (auto-calculates split lines) and split-by-count modes, with an interactive UI for adjusting split positions and feature parameters.

Cutout-aware clipping. Split lines are trimmed against interior cutouts so cut paths never travel through a hole. Lines are Liang-Barsky clipped at region boundaries and arcs/circles are iteratively split at their intersections with the region box, so a cutout that straddles a split correctly contributes material to both sides. When a cutout fully spans the region between two splits, the material breaks into physically disconnected strips — the splitter detects the connected components via endpoint connectivity, nests any remaining holes inside their outer loops by bounding-box and point-in-polygon containment, and emits one drawing per strip.

Post-Processors

Post-processors convert nested layouts into machine-specific G-code. They are loaded as plugin DLLs from the Posts/ directory at runtime.

Included:

• Cincinnati — Full post-processor for Cincinnati CL-707/800/900/940/CLX laser cutting machines with variable declarations, material library resolution, speed classification, kerf compensation, and optional part sub-programs (M98).

Custom post-processors implement the IPostProcessor interface and are auto-discovered from DLLs in the Posts/ directory.

Keyboard Shortcuts

Key	Action
Ctrl+F	Fill the area around the cursor with the selected drawing
F	Zoom to fit the plate view
Shift + Mouse Wheel	Rotate parts when a drawing is selected
Shift + Left Click	Push the selected group of parts to the bottom-left most point
Middle Mouse Click	Rotate selected parts 90 degrees
X	Push selected parts left (negative X)
Shift+X	Push selected parts right (positive X)
Y	Push selected parts down (negative Y)
Shift+Y	Push selected parts up (positive Y)
Arrow Keys	Nudge selected parts by an increment
Shift + Arrow Keys	Push selected parts in that direction

Supported Formats

Format	Import	Export
DXF (AutoCAD Drawing Exchange)	Yes	Yes
DWG (AutoCAD Drawing)	Yes	No
Excel BOM (Bill of Materials)	Yes	No
G-code	No	Yes (via post-processors)
.nest (ZIP-based project format)	Yes	Yes

Nest File Format

Nest files (.nest) are ZIP archives containing:

• nest.json — JSON metadata: nest info (name, customer, units, material, thickness, assist gas, salvage rate), plate defaults, plate options (alternative sizes with cost), drawings (with bend lines, material, source path, rotation constraints), and plates (size, quadrant, grain angle, parts with manual lead-in flags, cut-offs)
• programs/program-N — G-code text for drawing N's cut program (may include variable definitions and $name references)
• programs/program-N-subs — Sub-program definitions for drawing N (M98/G65-callable blocks for repeated features like holes)
• entities/entities-N — Original source entities for drawing N (preserved from DXF import with per-entity suppression state for round-trip editing)
• bestfits/bestfit-N — Cached best-fit pair evaluation results for drawing N, keyed by plate size and spacing (optional)

Status

OpenNest is under active development. The core nesting workflows function end-to-end — from DXF import through filling, splitting, cut-offs, and G-code post-processing. Contributions and feedback are welcome.

License

This project is licensed under the MIT License.