Custom made upgrade to laser cutter from old rotary blade Prosail Cutter

LM Sail had posted on the forum interesting video he have found on youtube.

Unfortunately I did not found more info about this setup (components, etc.). I just know that Prosail guys did not work on this upgrade. Anyway who have time and knowledge this can be rough guide how to upgrade rotary blade to laser cutter.

Auto nesting - Prosail vs NestFab

Finally I found time to test Prosail auto-nesting module. I took Nestfab results as reference for performance judgment.

I have done three tests. The longest time I left auto-nesting to run was 10min but in practice I believe nobody will wait more then 5 mins. So below results are the best within 5 min. Only 180 degrees rotation was allowed. Test where done with 1mm (for just plotting) and 10mm (for cutting) gap between panels

First test was tri-radial genoa with fun-cut patches (66 items):

	Prosail		Prosail (pair)		Nestfab standard		Nestfab Ultra
Panel Gap	Time	Percent	Time	Percent	Time	Percent	Time	Percent
1mm	4:34	86.7%	2:09	89.7%	1:39	76.39%	1:10	90.26%
10mm	4:48	84.2%	3:51	87.3%	2:00	76.39%	1:30	87.17%

Second test was true radial gennaker with plain patches.

	Prosail		Prosail (pair)		Nestfab standard		Nestfab Ultra
Panel Gap	Time	Percent	Time	Percent	Time	Percent	Time	Percent
1mm	4:50	85%	4.19	86.2%	2:08	75.67%	1:30	90.14%
10mm	3:08	83.4%	4:28	85.8%	2:14	77.63%	1:32	88.89%

Third test was small radial patches for 36 foot mainsail (72 items).

	Prosail		Prosail (pair)		Nestfab standard		Nestfab Ultra
Panel Gap	Time	Percent	Time	Percent	Time	Percent	Time	Percent
1mm	2:26	78%	3.11	81.7%	1:00	74.65%	1:39	86.87%
10mm	2:18	70.1%	1:14	74.1%	4:32	63.6%	1:39	78.9%

Nestfab ultra is performance winner. The fastest and with the best utilization. It is well connected to modern software (SailPack and Smar-Azure) so there is no need for import/export.

Nestfab standard is not useful at all. I think that creators of Nestfab use standard version just to give you comparison dialog with ultra version. They use that as marketing tool to convince you to buy ultra option. You should take their numbers with reserve because they do not show you other calculations. For example most of the time you will manually nest panels with much better utilization then standard option within 3-5 min.

Prosail auto-nesting is sometimes performs very good (almost as Nestfab ultra) and sometimes not so good. Anyway it will always have better utilization then manual nesting within 3-4 min (and often much quicker). Pair option usually give you better results quicker but for some jobs it is not suitable as utilization will not be so good. So if you do not get 85% utilization within 3 min with pair option try without it. Maybe you will get better utilization but be aware that it will need more time.

Added on 16.05.2016:

I forgot to write that Prosail auto nesting is quite simple with just tree options:

1) Rotate panels 180 deg

2) Pair similar panels

3) Panel gap

So there are not possibility to set size of sheets (fabric), more detailed rotation, priority, ... All those options are available in Nestfab and that gives you much more flexibility with your nesting.

Switching Open Sailmakers forums to Google Group Open Sailmakers

Today I have shut down opensailmakers.org forum site (http://forum.opensailmakers.org) as it did not attract community. To spare me some time fighting with spam and maintaining the site I decided to create google group Opensailmakers with same purpose.

All professional sailmakers (and related professionals like sailcloth produces, hardware suppliers, sail-making software developers, ... ) are welcome to join group. I hope to see you there :)

Challenge Sailcloth Matrix Weaves

Recently Challenge Sailcloth announced their new style called Matrix Weaves.

Here is quote from Challenge Sailcloth announcement:

Matrix is intended for performance oriented sailors who want shape holding ability combined with enhanced strength. The cloth provides great handling and excellent durability. Matrix is a completely unique construction that utilizes DoubleBeam² technology that has added extra strength that cannot be found in other light weight sailcloth styles.

For more info can be found at http://www.challengesailcloth.com/matrix

ProSail version 4 released

20 days ago Armstrong-White Automation (NZ) Ltd announced release of  version 4 of their ProSail software. This is well known and easy to use sailmaking software which is on market for decades.

This update is essentially a nesting and plotter software update. The most notable changes are:

• auto-nesting module
• straight blade attachment for cutters
• arc smoothing for improved plotting and cutting

Dimenssion-Polyant 2016 News

Dimension-Polyant has released product guide for 2016. Main news are:

• Carbon Sport – our new line for Club Racing Sails
• LITE SKIN - With our specially engineered surface structure (patent pending) we could replace the former double taffeta styles. The laminates become substantially with just a minimal loss in chafe resistance. Available on GPL and Carbon Sport styles. Also it is available to order it as PSA Laminated Patch Material
• FLEX® Ultra – last year’s newly introduced line got completed with SL (super light) and H+ (heavy plus) versions
• UVM® Light Beige – due to the increased demand at Classic Yachts we have implemented four AP styles again in our standard range without any minimum order quantities.

Auto-nesting

Last year many sail design software producers have included auto nesting option in their software. Mainly it is NestFab solution used. I was quite interested in this modules but also in other similar solutions. This article is quick overview of my findings.

Most manual nesting jobs sailmaker can do within average 15min with efficiency between 80-95% depends on sail type and cut (and different materials (colors) used and roll availability). So my quest was to find solution which can do better efficiency as first condition and better needed time as second condition (but not so important as auto-nesting time it is computer time not yours).

NestFab

There are to versions of NestFab.

First one is Standard which is very slow and not efficient. No meter how long I let it to run it could not reach better then 80% efficiency. Small gaps between panels make it really slow to get any solution. So Standard engine did not satisfy my first condition. This version cost $2200 per copy.

Second one is Advance version. This version is very quick and efficient (within 100sec 88%efficiency, within 700sec more then 90%). So this is very good candidate for sailmakers. Regarding price it is add-on to standard version. This add-on costs $1250 per year or $5000 for perpetual use. You will have to calculate your savings based on number and kind of jobs you mostly have to see is it worth investment.

Also good thing is that SailPack (you have to buy it as sailpack add-on with little bit different prices) and SmarAzure (I don't know their purchase policy) have implemented interface to Nestfab which will save you time with file export/import.

NestFab have its online variant http://mynesting.com/ but it uses Standard version. Price is $7-$4 depending on quantities which is quite higher than similar service NestLib online.

RhinoNest

This is add-on to Rhino 3D. It is reasonably fast but not efficient (similar to NestFab standard). It did not satisfied my first condition. Its price is quite low 500EUR. But you have to have Rhino which is 1000EUR.

To my knowledge there is no interface between sail design software so you will have to deal with export/import.

NestLib Online

NestLib Online as its name says is online nesting solution. You have to upload your files to server and start nesting job. It is free to try but optimized option with better efficiency is not available in free version. With optimized option activated it is quite slow (more then 60min) and you still do not get satisfying efficiency (little better then NestFab Standard version).

Price is 2$ per downloaded job. So you can run many jobs but you pay just ones you download files afterwords.

Again to my knowledge you have to deal with export/import by yourself.

There are probably many other nesting software which I have not tested so if someone did please write comment here about your experience.