Most nesting software is built with laser cutting in mind. When plasma shops try to use it, they run into a wall: kerf settings that top out at 0.5 mm when they need 3 mm, no heat-affected zone controls, and DXF parsers that choke on the types of geometry that come out of structural steel CAD work.

I built Lapas to handle both, which meant spending a lot of time talking to plasma shop operators about what they actually needed. This guide is the result of those conversations, plus a comparison of every serious nesting tool available for plasma in 2026.

What makes plasma nesting different

The requirements are genuinely different from laser work, and they’re worth understanding before evaluating any tool.

Larger kerf

Plasma kerf is typically 1.5–4 mm depending on material thickness, amperage, and gas. A 3 mm kerf on a job with 150 parts across multiple sheets adds up, so part spacing must account for it or parts come out undersized. Hypertherm’s published cut charts for the Powermax105 show 2.4–3.8 mm kerf on 12–25 mm mild steel at 105A, roughly 10–15x wider than a fiber laser on the same thickness.

For comparison, laser kerf is 0.1–0.3 mm. Many nesting tools are built with laser cutting in mind and treat kerf as an afterthought. For plasma, it isn’t.

Heat-affected zone

Plasma cuts produce a significant heat-affected zone (HAZ) extending 3–8 mm from the cut edge depending on material and speed. For structural parts that will be welded, the HAZ can affect weld quality if two plasma cuts run too close together on the same sheet.

Good plasma nesting practice: add minimum part spacing of 2–5 mm beyond kerf (not just the beam width) to keep cuts from thermally interacting.

Thicker material

Plasma is typically used on steel from 4 mm to 50+ mm. Thicker materials require slower cutting speeds, wider kerf, and more aggressive lead-in/lead-out geometry. Some nesting tools generate lead-in points automatically as part of the nest, which matters for plasma where lead-ins directly affect cut quality and sheet layout.

File formats

Most plasma CNC controllers run G-code or plasma-specific formats (SheetCam post-processors, Hypertherm’s Pronest format, ESAB’s Columbus format). A nesting tool that only exports DXF may require a separate CAM step. A tool that generates G-code or post-processable output directly reduces workflow steps.

What to look for in plasma nesting software

Kerf width control — Adjustable kerf with separate minimum part spacing field. Minimum: can you set a 3 mm kerf with 2 mm additional spacing?

Lead-in/lead-out handling — Does the nesting step place lead-ins, or is that left to CAM? Either is acceptable, but know which you’re dealing with.

True-shape nesting — Essential for plasma shops cutting irregular brackets, flanges, gussets, and structural shapes. Rectangular nesting wastes too much material.

DXF import reliability — Plasma shops typically work with DXF files from AutoCAD, SolidWorks, or FreeCAD. The nesting tool must handle the full DXF spec including complex polylines and splines.

Rotation handling — For structural steel parts where grain direction matters (e.g., rolled steel plate with directional properties), you need the ability to restrict rotation angles.

Common line cutting — Placing two parts to share a single cut path reduces kerf loss and cut time. Not all tools support it, but it’s valuable for plasma shops cutting large quantities of rectangular or simple-shaped parts.

Output format — DXF for further CAM, G-code directly, or proprietary format for your controller.

Plasma nesting software options in 2026

Lapas — browser-based, free tier available

Price: Free (5 jobs/month) / Pro at $49/month
Platform: Browser (any OS)
Best for: General plasma shops, shops that want a quick no-install evaluation, multi-OS teams

Lapas handles DXF files from all major CAD tools, supports adjustable kerf and part spacing for plasma workflows, and performs true-shape irregular nesting. It runs in the browser with no installation on Windows, Mac, Linux, or shop-floor tablets.

The free plan covers 5 nesting jobs per month with no credit card required, so you can test it on actual production files before committing. The Pro plan adds unlimited jobs, PDF report export, and the deeper metaheuristic engine.

Kerf handling: Adjustable kerf + separate minimum spacing — suitable for plasma
DXF import: Full DXF spec, handles complex geometry
Export: DXF (for CAM), PDF report, G-code
Offline capability: No — requires internet connection

Pros: No install, free tier, active support, works on any device
Cons: Requires internet, no native Hypertherm/ESAB post-processor integration

Deepnest — free, offline

Price: Free (open source)
Platform: Windows/Mac/Linux desktop app
Best for: Shops that need a completely free, offline option and are comfortable with unmaintained software

Deepnest is a free, open-source nesting tool that hasn’t been updated since 2021. For plasma cutting specifically, its kerf handling is basic: you can set a spacing value, but the interface is less intuitive than purpose-built plasma tools.

The biggest limitation for plasma shops: Deepnest was built primarily for laser cutting and fabric nesting. Its DXF parser struggles with complex geometry from newer CAD exports. If your DXF files are simple, it may work fine. If you’re exporting from Fusion 360 or newer SolidWorks, expect import issues.

Kerf handling: Basic spacing parameter
DXF import: Works for simple geometry, unreliable for complex DXF
Export: SVG, DXF
Offline capability: Yes

Pros: Free, offline, no subscription
Cons: Unmaintained (last updated 2021), no PDF export, unreliable DXF import, no browser version

ProNest LT — Windows, Hypertherm-focused

Price: $29.99/month (no free tier, 7-day trial)
Platform: Windows desktop only
Best for: Shops running Hypertherm plasma systems, Hypertherm SureCut integration

ProNest LT is built by Hypertherm, the plasma cutter manufacturer, and it shows. The tool has deep integration with Hypertherm’s SureCut technology, which optimises cut parameters (amperage, speed, gas pressure) per part geometry for consistent cut quality.

For shops running Hypertherm Powermax or XPR series machines, ProNest LT provides cut chart integration that automatically selects the right parameters for each thickness. This is genuinely valuable and not something general nesting tools replicate.

Outside Hypertherm hardware, ProNest LT is a solid but pricey option at $29.99/month with no free tier. It’s Windows-only, requires installation, and the interface hasn’t changed dramatically in several years.

Kerf handling: Excellent — built for plasma specifically, cut chart integration
DXF import: Good
Export: DXF, G-code, Hypertherm post-processor formats
Offline capability: Yes

Pros: Best Hypertherm integration, cut charts, mature product
Cons: Windows only, no free tier, $29.99/month from day one

SigmaNEST — enterprise

Price: $5,000–$20,000+/year
Platform: Windows
Best for: Large fabrication shops, multi-machine environments, shops needing ERP integration

SigmaNEST is the industrial-grade option. It handles multi-machine scheduling, ERP integration (SAP, Epicor), remnant tracking, and highly sophisticated nesting algorithms optimised for complex plasma, laser, and waterjet environments.

For a typical plasma shop doing $200k–$1M/year in cuts, SigmaNEST is overkill. For a large fabricator running 10+ CNC machines with tight ERP integration requirements, it’s the serious option.

Kerf handling: Full — with HAZ compensation options
DXF import: Full
Export: All major formats, machine-specific post-processors
Offline capability: Yes

Pros: Most capable product, enterprise integration
Cons: Expensive, requires dedicated training, overkill for most shops

SVGNest — free, browser-based, basic

Price: Free (open source)
Platform: Browser
Best for: Hobbyists, makers, occasional cutting jobs — not production plasma

SVGNest is a browser-based, open-source nesting tool primarily designed for SVG files. It supports DXF via file conversion, but DXF import is not its strength.

For plasma cutting specifically, SVGNest lacks kerf configuration appropriate for plasma (the spacing controls are basic), no G-code export, and no PDF reporting. It’s fine for a maker cutting occasional parts; it’s not suitable for a production plasma shop.

Kerf handling: Basic
DXF import: Limited (SVG-first tool)
Export: SVG, basic DXF

Pros: Free, browser-based
Cons: SVG-first (not DXF-first), no kerf controls appropriate for plasma, no PDF/G-code

Comparison table

Feature	Lapas	Deepnest	ProNest LT	SigmaNEST
Price	Free / $49/mo	Free	$29.99/mo	$5k–20k+/yr
Platform	Browser	Desktop	Windows only	Windows
Free tier	Yes	Yes (fully free)	7-day trial	No
True-shape nesting	Yes	Yes	Yes	Yes
Plasma kerf controls	Yes	Basic	Excellent	Excellent
DXF import	Full spec	Basic	Good	Full spec
Live preview	Yes	No	No	No
PDF report	Yes	No	No	Yes
G-code export	Yes	No	Yes	Yes
Hypertherm integration	No	No	Yes	Yes
Active development	Yes	No (2021)	Yes	Yes

Which should you choose?

Use Lapas if:

You want a quick, no-install evaluation on real files
You’re not tied to Hypertherm hardware
You work on Mac, Linux, or need tablet access
You want a free tier with no time limit

Use ProNest LT if:

You run Hypertherm plasma systems and want SureCut integration
You need machine-specific cut charts built into your nesting workflow
You’re on Windows and don’t mind the $29.99/month from day one

Use Deepnest if:

You need completely free, offline nesting forever
Your DXF files are relatively simple (no complex splines or nested blocks)
You’re comfortable with a tool that hasn’t been updated since 2021

Use SigmaNEST if:

You run a large multi-machine fabrication shop
You need ERP/MES integration
Budget is not a limiting factor

Getting started with plasma nesting in Lapas

Export your parts as DXF from AutoCAD, Fusion 360, SolidWorks, or your plasma CAM
Create a free Lapas account (no credit card required)
Upload your DXF files, set quantities
Set sheet size, kerf width (typically 1.5–3 mm for plasma), and minimum spacing (add 1–2 mm on top of kerf for HAZ clearance)
Run the nest, review utilization
Export DXF for your CAM software, or G-code directly if your machine accepts standard G-code

The free plan covers 5 full nesting jobs per month, enough to evaluate on your actual production files and compare material utilization against your current method.

Plasma Cutting Nesting Software — Free and Paid Options (2026)