Microvellum Knowledge Network

Introducing the Next-Gen Optimizer: Now in Beta

We’re excited to introduce a new generation of optimization tools—now available in beta. This release marks a major step forward, featuring an all-new optimizer built from the ground up with a modern, flexible architecture and a powerful genetic algorithm. Whether you're using block nesting or sawing, you'll now have access to smarter, more adaptive optimization options designed to improve efficiency and expand what's possible. Read on to learn what’s new, how to get started, and how to share your feedback.

What to Expect in the Beta Release

The beta is available to anyone currently using our block nesting and sawing optimizers. Once you receive the update, you'll see a new Optimizer Type setting in the Processing Station. The existing optimizer is now labeled Legacy, and the new optimizers will appear in a drop-down menu as Beta. This makes it easy to opt in and start testing.

Because the new optimizers introduce additional settings, we’re also providing updated documentation and tooltips to help you get familiar with them. And if you ever want to switch back, you can simply change the setting back to Legacy. 

    Key Differences: Mathematical vs. Genetic Optimization

    Our current nesting and sawing optimizers use a mathematical algorithm with fixed rules, meaning they follow a set mathematical formula to arrange parts on a sheet. Given the same input—settings, material, and parts—the optimizer will generally produce the same result.

    The new optimizer takes a completely different approach. It uses a genetic algorithm, which mimics natural selection by evaluating multiple layouts, learning from the best ones, and continuously improving. Unlike the legacy mathematical optimizer, which always produces consistent results based on rules, the genetic optimizer explores different possibilities with each run. This leads to variable results that adapt and improve over time—the longer it runs, the more patterns it evaluates, refining layouts for greater efficiency.

    One of the biggest advantages of this approach is flexibility. The legacy optimizer wasn’t built for expansion, but the new optimizer allows us to introduce new strategies without changing the core logic—making future improvements easier and faster.

    New Processing Interface & Controls

    The new optimizer includes an updated processing interface that gives you more insight and control over the optimization process.
    You can now:
    • Cancel/Abort or Accept optimization for specific processing stations
    • Accept optimization results and complete processing
    • Stop the entire process at any time (no more waiting for it to finish)
    The new interface also provides greater visibility into what’s happening during processing. You'll see:
    • Sheets of material used
    • Yield, scrap material, and wastage percentages
    • Number of evaluated patterns
    • Number of optimized parts
    • Estimated optimization time
    If you're using multiple processing stations, you’ll see progress for each one in a single, tabbed interface—making it much easier to monitor and manage optimization in real time.

    New Beta Feature Documentation

    The following articles are available for to learn about any of the new optimizer's changes or new setting options: 

    Upcoming Improvements for Large Parts

    To be transparent, we’ve identified the need for an additional optimization strategy for extra-large parts—those that exceed 75% of the sheet size. We’re currently working to improve how smaller parts fit into the remaining space to maximize yield. Once this strategy is ready for end-user testing in a future beta cycle, we’ll let you know.

    True Shape Progress

    We're making great progress on our True Shape algorithm, and early results are shaping up nicely. That said, it’s not quite ready for this beta cycle. We're continuing to fine-tune the functionality to ensure it meets the quality and performance standards we’re aiming for. Once it’s ready, we’ll keep you in the loop.

    Beta Feedback

    This isn’t just an update—it’s a brand-new optimizer, built from the ground up. Your feedback is essential to helping us refine and improve it. Real-world testing and input from users like you allow us to catch issues early, identify areas for improvement, and ensure the final release delivers meaningful value.
    To share your feedback, create a new case in the Microvellum Portal and select “Beta Feedback” as the case type.

    We welcome all types of input—what you like, what could be improved, and any issues you encounter. If you're reporting a problem, please include the relevant work order and processing station to help us investigate effectively. Our team will review each case and respond or escalate as needed.

    ............

    Again, we’re excited to release this next-gen optimizer, and we look forward to hearing your feedback as you begin working with these new tools.

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