Tube, Pipe & Profile Forming calculator

Tube Nesting Calculator

Find how many identical stock bars cover an order of identical cut tubes. Enter stock and cut lengths, release kerf, end trim and the order count.

What this calculator does

  • Plan whole stock bars for an order of identical cut tubes.

Formula used

  • Pieces per bar = floor((stock length − total trim) ÷ (cut length + release kerf))
  • Bars required = ceil(requested tubes ÷ pieces per bar)
  • Unused piece slots = bars required × pieces per bar − requested tubes
  • Order yield = requested tubes × cut length ÷ (bars required × stock length) × 100
  • Remaining length = bars required × (stock length − trim) − requested tubes × (cut length + release kerf)

Inputs explained

  • Stock Tube Length: Purchased bar length from the stock specification.
  • Finished Cut Length: Finished axial length on the part drawing.
  • Kerf per Release Cut: Measured material removed by each part release cut.
  • Total Trim per Bar: End trim and trim-cut losses reserved per stock bar.
  • Requested Cut Tubes: Uniform cut tube quantity on the customer order.

How to use the result

  • Best suited to uniform cut order Planning, alternative stock length comparison.
  • Does not optimize mixed part lengths, profiles, contours or shared cuts. No allowance for rejected parts; add an approved quantity allowance to the order.

Current U.S. benchmarks

  • The producer price index for steel mill products stands at 381.162 (BLS, Aug 2026), up 23.4% from a year earlier. Quotes priced off last quarter's material cost miss this move.

Common questions

  • Can this nest several different cut lengths? No. The model uses one finished length and one stock length. A mixed order requires a separate nesting program with every part length and quantity.
  • Why is the last bar included in yield? You purchase the whole bar even when the order uses only part of it. Order yield divides requested finished length by all purchased stock length.
  • Is remaining length all scrap? No. It is uncut stock after the requested parts, release kerfs and trim. Assess each individual remnant for reuse.
  • How do I include a reject allowance? Increase the requested cut count using your approved allowance. This model supplies no default rejection rate.

Last reviewed 2026-10-06.