When cutting high-strength steels, nesting becomes even more critical, as improper nesting can lead to undesirable effects such as softening of cut parts or distortion caused by the relaxation of internal stresses.

Softening of Cut Parts
This issue is especially relevant for Hardox® steels, which derive their exceptional wear resistance from their high hardness. These materials have a relatively low tempering temperature—meaning, if heated above a certain threshold, they can lose their hardness.
These maximum allowable temperatures are listed in the Cutting of Hardox® brochure and in the CutCalc application, see also Preheating temperature recommendations. For example, if all parts are cut from one end of the plate in sequence, the first piece will maintain its hardness. However, the heat introduced into the plate during that first cut will raise the overall temperature of the surrounding area. As a result, the second piece—cut immediately afterward and nearby—may experience slight softening, while subsequent parts are at an even higher risk of losing hardness. Always monitor the plate temperature, especially when cutting small parts, as they can heat up rapidly and lose hardness more easily. „Add link to preheating temperatures“

To avoid this, heat input during cutting must be evenly distributed across the plate. This means that after cutting a part from one corner of the plate, the next part should either be cut from the opposite corner or delayed until the plate has cooled sufficiently.

Distortion Due to Internal Stress Relaxation
Distortion, or warping, can occur when internal stresses are unevenly relieved due to localized heating. This typically happens when several cuts are made in close proximity without proper planning.

To minimize this effect, nesting and cutting sequences should be designed to maintain thermal balance across the plate. In other words, parts should be cut in a symmetrical and staggered order to prevent localized stress release.

Proper nesting is not only about saving material—it's a critical step in preserving the mechanical properties of high-strength steels and ensuring dimensional accuracy. A well-planned nesting strategy leads to higher quality, longer-lasting parts, and fewer reworks.

Example of nesting in ProNest software.