Mastering Volume Packing and Part Orientation for Faster, Cost‑Effective Additive Manufacturing

According to a recent industry survey, additive manufacturing (AM) firms are prioritising faster project turnaround and lower operational costs. More than half of the respondents are already treating AM as a production tool rather than merely a prototyping solution.

While the strategic goals are clear, the path to achieving them remains complex. A critical, often under‑emphasised element is an effective volume‑packing (nesting) and part‑orientation strategy, which can dramatically increase build efficiency, reduce waste and improve quality.

Laying the Foundation for Effective Nesting and Part Orientation

A thoughtfully designed nesting and orientation plan unlocks the full potential of your printers, enabling more parts per build without compromising surface finish or structural integrity. Because each AM project presents unique variables, there is no single “best” approach.

Before configuring nesting or orientation, define the role of each part in the build and its surface‑finish requirements. These factors dictate the part’s orientation, which in turn influences how other components can be nested around it. The impact of orientation varies by technology: it has a modest effect on SLS builds (though it can lengthen build time) and a substantial effect on SLA and FDM, where orientation can dictate overhangs, support needs and final part quality.

The Value of Strategic Automation

As the number of influencing variables grows, many AM teams are turning to sophisticated software platforms that automate nesting and orientation. These tools employ proprietary algorithms to optimise part placement and orientation, and research from institutions such as the University of Nottingham continues to refine these methods.

Two of the most respected solutions on the market are Materialise Streamics and Autodesk Netfabb. Below is a concise comparison of their strengths and limitations.

Materialise Streamics

• Direct integration with a wide range of machines via multiple file formats
• Seamless workflow when paired with other Magics suite tools
• Build‑optimisation and shape‑sorting features that align builds around a master part’s orientation
• High customisability with six alignment entities and user‑defined coordinate systems

Limitations: Premium pricing compared to other solutions.

Autodesk Netfabb

• Configurable packing parameters (density, speed, etc.)
• Orientation options relative to bounding boxes or adjacent parts
• Automatic arrangement based on out‑box or real contours, offering flexibility
• Includes the Monte‑Carlo Packer as an alternative packing tool

Limitations: Nesting capabilities are not included in the standard package.

Making the Right Investment

When selecting a platform, ensure it is compatible with your production environment. Industrial‑grade AM typically requires the full, server‑based versions of these tools, not the desktop editions, because of their advanced nesting and orientation features and their ability to handle large‑scale workflows. Adequate hardware—high‑performance workstations or a robust network server—must be in place to run the software efficiently.

Execution speed is a critical factor: the time spent on nesting and orientation can directly influence overall build times. By meeting the software’s minimum system requirements and allowing the algorithm sufficient runtime, you reduce bottlenecks and improve throughput.

In summary, investing in the right AM software and infrastructure empowers you to develop a resilient nesting and orientation strategy. This foundation supports both rapid prototyping and full‑scale production, ensuring you extract maximum value from your printers.