Nesting is the process of arranging parts efficiently on a material sheet to minimize waste. It is a crucial step in shipbuilding that directly impacts material utilization and production costs. The goal is to fit as many parts as possible onto a sheet while considering factors such as part shape, size, and orientation. This article will guide you through the nesting process in MasterShip, building upon detailed 3D assembly and part data created in preceding design stages.
Fun fact: Nesting problems are actually considered a complex mathematical optimization problem, similar to those found in other industries like textile manufacturing (optimizing fabric layout) and logistics (loading trucks efficiently).
Making nestings with MasterShip
This video demonstrates how to makes nestings for parts and stiffeners in MasterShip. Next to that, we have listed some of the best practices from the engineering perspective:
- Determining plate dimensions and clearances: To maximize material utilization, it's essential to determine the required plate dimensions and clearances. The SHIPCREATEPLATE function allows you to define the dimensions and material of the plate needed. The use of this function is also the starting point of nesting with MasterShip.
For clearance between parts and plate edges, a distance of 20mm is typical, and 10mm between parts. However, it's advisable to consult with the cutting machine operator to determine the most suitable clearances for specific materials and cutting processes. MasterShip's NC Generator allows you to define these parameters for optimal nesting efficiency. You can do this here:
SHIPOPTIONS > NC Generator > Nest properties. Turn the settings-level to 'project' to modify these fields.
- Importing and preparing parts: Accurate part data is vital for successful nesting. Use the SHIPPARTSSELECTOR to import parts from specific drawings, ensuring correct quantity, material, and thickness. Consider grouping parts by production unit for improved logistics, although this might impact nesting efficiency. A trade-off might have to be made.
To ensure correct marking placement, mirror parts that require marking on the opposite side. MasterShip automatically mirrors parts when the 'Mark on other side' box is checked. See the article How to apply part markings for more information on this.
- Part nesting: Effective nesting involves selecting the right method and properties to achieve a balance between efficiency and speed. MasterShip offers both SHIPAUTONEST for fully automatic nesting and SHIPNESTPART for semi-automatic nesting of different parts. Often, automatic nesting does the job very well. Semi-automatic nesting or even manual nesting is done in case of specific user requirements.
- Mark part information: This enhances the logistics on the shipyard. Having a part ID (PosNum), production unit and any treatment information helps sorting out parts.
In MasterShip, this is typically done after the plate nestings are made. Using the command SETTEXTINTPLATE you can get the part information as marking text in the plate.
Expert tip: In MasterShip, the default is "partID / Production unit - sub assembly / operations". To tailor this data to your shipyard, you can modify the format and amount of part data to print on the part. Here is how: How to modify marked part data.
Stiffener nesting
The nesting of stiffeners is done in the MasterShip Organiser. MasterShip Organiser > Calculations > Stiffeners > Sawlist. Executing this action will generate a purchase list and stiffener saw list, which can be found in the reports.
Output and next steps
Efficient nesting results in optimized material utilization, reduced waste, and streamlined production processes. The output includes nesting efficiency data, purchase lists, and optimized plate part and stiffener nesting. The next step is to generate NC code for cutting based on the created nestings.
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