Thermoforming & Vacuum Formed Products worked example

Nesting Yield at 68% target nesting yield: a worked example in thermoforming & vacuum formed products

Suppose target nesting yield falls to 68%. This page works the full calculation at that level so you can see exactly which result moves and by how much. Nesting yield tells you how efficiently your part cavities are packed into the plastic sheet and how many of those nested parts are lost to scrap — the two levers that decide how much of an expensive extruded sheet becomes saleable product versus regrind.

The inputs for this scenario

  • Parts scrapped from the nested layout: 8 units (held at the documented default)
  • Total part cavities in the sheet layout: 250 units (held at the documented default)
  • Target nesting yield: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Nesting Yield rate = affected amount ÷ total amount.
  • Rate works out to 3.2 % at these inputs, and this is the headline figure for the scenario.
  • Gap to target works out to 64.8 points at these inputs.
  • Affected count works out to 8 count at these inputs.
  • Total count works out to 250 count at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where target nesting yield sits at 95% and the headline result is 3.2 %, this scenario lands almost exactly on the baseline at 3.2 %.
  • It computes the scrap rate as affected parts divided by total nested cavities, and reports the gap in points between that rate and your target yield. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Rate: 3.2 % (headline result)
  • Gap to target: 64.8 points
  • Affected count: 8 count
  • Total count: 250 count

Run it with your numbers

  • To rerun this with your own numbers, open the live Nesting Yield calculator, set target nesting yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.