CUT PLANNING
Cut Lists and Saw Kerf
A reliable cut plan reserves material for every blade path and trim cut, then tests the layout against grain, defects, and safe handling.
SHORT ANSWER
The working rule
Measure the kerf made by the installed blade in representative stock, then model every cut that separates parts—including initial squaring and final trimming. Finished lengths plus one generic kerf per part are not enough for a dependable plan.
Define the finished part before nesting
A cut list should name the finished length, width, thickness, quantity, grain direction, and any show-face or matching requirement. Add machining notes for parts that will be jointed, planed, tenoned, or trimmed after glue-up. Those operations require blanks larger than the final dimensions, and the extra belongs in the blank size rather than being hidden in a waste percentage.
Separate solid-wood and sheet-goods planning. Solid wood is constrained by grain, defects, and milling sequence; sheet goods are constrained by panel orientation, edge quality, and handling. In both cases, identify the reference edge and decide which dimensions are rough blanks versus final cuts before optimizing the layout.
Measure the process kerf
Kerf is the material actually removed by a cut. It varies with blade plate and tooth geometry, runout, setup, and the material being cut. Make a representative cut, bring the pieces back together, and measure the missing width—or compare the stock before and after the cut. Record the value with the blade and machine used.
Count blade paths, not just pieces. Crosscutting three separate parts from one board normally needs a separating cut between parts plus any end-squaring and final-trim cuts. A shared boundary can save a cut only if the resulting edges and dimensions are acceptable. Leave room to establish a straight reference edge before treating a stock edge as finished.
Apply constraints before chasing yield
Mark knots, checks, wane, cup, and grain runout on the stock sketch. Reserve long, matched, or highly visible parts first; fill around them with shorter internal components. Keep grain direction fixed for structural or appearance reasons. A layout with a higher theoretical yield is not better if it turns a defect into a weak joint or flips a show face.
Include a recovery margin rather than planning every cut at the absolute limit. Stop blocks, fences, and tape measures have tolerances; stock can move after ripping; and an edge may need another pass. Put that margin on the operation that needs it so the cut list explains where the material went.
Make the sequence safe and repeatable
Optimization does not override safe machine use. OSHA’s woodworking standard requires guards and appropriate anti-kickback provisions for covered equipment, and its table-saw guidance stresses correct blades, adequate support, and keeping the stock aligned. Do not preserve a risky offcut merely because the layout says it has value.
Print or mark the sequence, label parts immediately, and check the first repeated cut before producing the batch. Re-measure the remaining stock after any deviation. If a blade, setup, or stock condition changes, update the kerf and layout rather than relying on the original optimistic plan.
A practical workflow
- List finished parts, then assign oversize blank dimensions for jointing, planing, and final trimming.
- Measure the installed blade’s real kerf in representative stock and identify every separating and squaring cut.
- Place constrained parts first, preserving grain direction, show faces, and defect exclusions.
- Review the sequence for stable support and guarding; label and verify the first part before batch cutting.