Tutorial: How I Get Tighter Nesting Results in Arrange Master

The new Genetic Algorithm is more capable, but there is another way to improve the density of a rectangular layout: use the container itself to increase packing pressure.

This is the workflow I currently use when preparing irregular vector objects for production.

Step 1. Prepare the Illustrator document

Create a new document with the required color mode and measurement units.

For CNC/Laser Cutting Preparation, verify that the document units match the dimensions expected by your production equipment.

Step 2. Organize the artwork

Place your vector objects in the document.

If your artwork includes cut lines, guides, QR codes, or additional print elements, organize them on separate layers.

On the lowest layer, create a rectangular container with the required width and an arbitrary height. Make it tall enough to hold the entire initial arrangement.

Save the document before working with a large collection of complex objects.

Step 3. Create the first arrangement

Select the objects and the container, then open Greedy Layout.

Enable Dense Packing, choose a small but production-safe Min. Spacing value, and set the Evolution Stepper to 1.

Choose a gravity direction. For a vertically elongated container, I recommend starting with X-Gravity.

Click Arrange and allow the calculation to finish.

Step 4. Inspect the occupied area

You will see the first arrangement and the position of its final edge.

Do not click Ok or Cancel yet. Keep the Arrange Master session active.

Step 5. Reduce the container height

Select the container and move its bottom edge upward, slightly beyond the current final edge of the object block.

Keep the original container width unchanged.

Click Arrange again.

The Genetic Algorithm now has less vertical space available and must reconsider how the objects fit together.

[SCREENSHOT 7 — The container-height technique]

Caption: After the first arrangement, move the bottom edge of the rectangular container upward and click Arrange again. Reducing the available height encourages tighter nesting.

Alt: Adobe Illustrator tutorial showing how to reduce the height of an Arrange Master Dense Packing container before recalculating the layout.

Step 6. Repeat while all objects still fit

If every object remains inside the container and you can still see unnecessary empty space, reduce the height again and repeat the calculation.

You may need several iterations.

Step 7. Change the search settings when necessary

Eventually, you will reach a point where further compression becomes difficult or one of the objects moves into Overflow.

This is the moment to try X/Y-Gravity or increase the Evolution Stepper.

Higher Evolution values allow the Genetic Algorithm to explore more combinations within the tighter container, although the calculation will take longer.

If the objects still cannot fit, restore a little container height and compare the results.

Step 8. Finalize the layout

Once you have found a satisfactory arrangement with no unwanted Overflow, inspect the minimum gaps and cut contours.

Click Ok to finalize the session.

[SCREENSHOT 8 — Before and after height reduction]

Caption: The same vector objects before and after several container-height adjustments. The width remains unchanged while the final occupied height is reduced.

Alt: Before and after comparison of vector material optimization in Arrange Master using iterative container-height reduction.

How Much Material Can This Save?

In my tests, this manual height-reduction technique has reduced the occupied rectangular area by approximately 8–10% compared with the initial arrangement without additional container compression.

The exact saving depends on object geometry, the selected gravity vector, allowed rotations, and the initial amount of unused space.

An automatic container-height compression mechanism is still something I want to improve further. For now, this iterative workflow is one of the most effective ways to push Dense Packing toward a tighter result.