The AutoBarSizer software determines optimized cutting plans for cutting steel profiles and other bar material (long material) into shorter parts (fixed dimensions). The generated solutions are characterized by a high degree of material utilization (utilization, yield), cutting losses are minimized.

Cutting plan calculated with AutoBarSizer with miter cuts and a reusable rest (green).

Optimize miter cuts in seconds

When mitering parts, AutoBarSizer also optimizes the nesting (interlocking) of the parts. For this purpose, it is sometimes useful to rotate the parts. Which rotations are permitted can be specified by the planner depending on the symmetries of the material and production requirements.

AutoBarSizer solves problems that arise during planning in rolling mills and at steel distributors, but also in the wood processing industry as well as at manufacturers and processors of all types of laths. The calculations for a usual size cutting plan take only a few seconds to a few minutes at most.

Benefit & added value

Mit einer computergestützten Optimierung von Längenkombinationen beim Zuschnitt von Stangenware lassen sich durch die bestmögliche Vermeidung von Schrott erhebliche Mengen an Material einsparen. This conserves resources and reduces production costs without compromising product and service quality.

By individually weighting residual recycling and residual generation, AutoBarSizer can also regulate residual stock levels and avoid unnecessary storage costs.

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Carina Göbel-Weidenbach
Carina Göbel-WeidenbachFinance & Controlling

Target groups

Providers of software solutions who would like to integrate optimization into their application, as well as larger companies who are willing to program or have programmed a corresponding connection to their IT systems.

To enable companies to get an impression of the software’s performance before programming a connection, Fraunhofer SCAI offers a demo user interface. This simple interface is not suitable for daily productive use.

Integration into existing software

AutoBarSizer is distributed as a pure geometric optimization engine and is intended for integration into other applications, for example plant control systems, MES or ERP systems. For this purpose, AutoBarSizer has an XML interface that can be accessed via standard input / output, via a file interface or as a server service. The software runs on all current Microsoft Windows operating systems.

Features of AutoBarSizer

Miter cut

  • material-specific symmetries of the profile to be observed when turning mitered parts
  • Minimum lengths for trapezoidal scrap parts between two mitered parts
  • Any miter angle
  • Miter orientation (lying / standing)
  • Specification of a sawing side on which a certain side of each part and bar must lie

Parts and material

  • Any number of different parts
  • Any number of different output lengths
  • optional maximum number of lengths used simultaneously
  • individual availability of the bars


  • front and rear trim (unusable areas at the beginning and end of the bar)
  • Saw blade thickness


  • Optimization over multiple materials with separate properties
  • Runtime and optimization strength controllable
  • Key figures support the evaluation of the calculated solutions

Rest and waste

  • one- or two-stage evaluation of generated remnants with individual minimum lengths
  • Weighing residual production against output
  • Preferential use of existing remnants
  • optional maximum length of produced waste per material


  • Scrap avoidance
  • Reduction of production costs
  • Regulation of residual stocks
  • Avoidance of unnecessary storage costs