Impact of minimum distance constraints on sheet metal waste for plasma cutting

We approached the two-dimensional rectangular strip packing problem (2D-SPP), where the main goal is to pack a given number of rectangles without any overlap to minimize the height of the strip. Real-life constraints must be considered when developing 2D-SPP algorithms to deliver solutions that will improve the cutting processes. In the 2D-SPP literature, a gap related to studies approaching constraints in real-life scenarios was identified. Therefore, the impact of real-life constraints found in the plasma cutting process in sheet metal waste was analyzed. A mathematical model from the literature was modified to obtain packing arrangements with plasma cutting constraints. The combination of size and number of rectangles, as well as strip width, was the main factor that affected the packing arrangement, limiting the allocation of rectangles and generating empty spaces. In summary, considering the sheet metal waste context, instances with smaller widths should be avoided in practical operations for high minimum distance constraint values, returning the worst packing arrangements. For low minimum distance constraint values, smaller width instances can be used in practical operations, as the packing arrangement is acceptable. Finally, this article can reduce material waste and enhance the cutting process in the sheet metal industry, by showing packing characteristics which lead to higher amounts of raw material waste.