Packaging Dieline & Box Blank Nesting
Nest box blanks, lids and dielines across corrugated sheets with 0-degree rotation for grain and scoring direction.
The problem: prototype runs eat board
A proof run of forty mailers across three sizes lands on a full corrugated sheet, and how much of that sheet you actually use depends entirely on how long you are willing to spend arranging blanks by hand. Flaps make it worse: every tab is a collision waiting to happen.
What NestPlug does instead
Select the blanks, set the sheet to the board you buy, and calculate. The engine packs the real dieline outline, flaps included, so a tuck flap nests into the shoulder of its neighbor instead of colliding with it. Rotation stays at 0° so grain and scoring direction survive, which is what corrugated actually cares about.
From proof to production
When the order outgrows the sheet, multi-sheet planning flows the remaining blanks onto additional sheets with the fill balanced, and sheet gap keeps sheet origins cleanly separated on the artboard so each sheet exports as its own file.
Dielines stay dielines
Apply moves the original blank, score lines and cut lines together, in place, still editable. Move a size, re-calculate, re-apply. The layout is a step in your process, not a separate file you have to babysit.
How this run was set up
- Sheet: 1200×800mm corrugated, 10mm edge padding
- Minimum distance: 6mm, rotation 0° for grain and scoring direction
- Result: 60 of 60 placed, 55% packed, cluster 42.5×22.3in
Questions
Do score lines and creases move with the blank?
Yes. Apply moves the original objects, every layer of them, so scores, cuts and print art stay registered.
Can I mix sizes on one sheet?
That is the point: nest the whole family, small mailers filling the gaps between large ones, in one calculation.
My sheets are bigger than the panel default. Fine?
Sheet width and height are free fields. Set them to the board you buy, in inches or millimeters.
Related: laser & CNC · sticker sheets · all use cases · Request a feature.