Circular Filter Disc Cutting & Yield Calculator
Compare straight and staggered circular-disc layouts on a rectangular mesh sheet. Enter overall sheet dimensions, side/end trims and the minimum edge-to-edge gap between discs.
Fixed regular layouts only. Counts are alternatives, not totals to add together. This tool does not optimize nesting or verify punching, laser cutting, mesh orientation or handling constraints.
Regular-layout alternatives
Usable rectangle:
Straight rows
discs
Material yield:
Unallocated area:
Staggered across width
discs
Material yield:
Unallocated area:
Staggered across length
discs
Material yield:
Unallocated area:
Yield uses finished-disc area divided by the original sheet area. Unallocated area includes trims, gaps and residual sheet; it is not necessarily reusable scrap.
Layout rules
Center pitch p = diameter + gap. Straight row spacing = p. Staggered row spacing = √3 × p / 2; alternate rows shift by p / 2. The first row starts one disc radius inside the usable boundary. Each complete disc must fit inside the usable rectangle.
The two staggered alternatives swap which sheet dimension is the row direction. Start rows use the unshifted pattern. Empty shifted rows may occur on very narrow sheets; compare with the straight-row alternative. No partial discs are counted.
Frequently asked questions
Is this the maximum possible cutting quantity?
No. It evaluates three fixed regular layouts. Other offsets, mixed layouts and nesting software can give different counts.
Is yield based on the usable or original sheet?
The original sheet. Side and end trims therefore reduce overall material yield.
Does the gap replace side trims?
No. Gap controls disc-to-disc clearance. Trims control clearance from the original sheet boundary and must be entered separately.
Can I use this for annular filter rings?
Only for outer-disc blank counts using the outside diameter. Inner holes and possible reuse of center cutouts are not included in yield.
Can staggered cutting change mesh direction?
The disc shape is circular, but manufacturing requirements may still specify warp/weft orientation. Check each layout against your drawing and process.
What if the disc does not fit?
The count is zero. If trims remove all usable width or length, the calculator reports an input error. Layouts over 100,000 rows must be split into smaller sections.
