Gang sheet nesting: 7 ways to fit more transfers on the same film

1. Allow rotation

Turning a design 90° often lets two rows fit where one did. ZoroPrint’s nesting tries both orientations for every piece when “Allow rotation” is on. The customer does not care which way it was printed.

2. Gap 2–3 mm, not 10

You need enough space to cut with scissors — 2–3 mm is plenty for a cutter, 4–5 mm if you cut by hand in a hurry. A 10 mm gap on 20 pieces wastes a whole row.

3. Margin

3.5–5 mm is the safe printable margin on Epson desktops. Going below it makes the head print off the film onto the rollers. Keep it, but do not add extra.

4. Big first, small last

Nesting algorithms place what they are given in order. Add or sort the large designs first so they take the corners; small logos and labels then drop into the leftovers.

5. Mix orders

Two half-empty sheets for two customers cost twice as much as one full sheet. Combine orders on one sheet, label each with the job label mark, and cut them apart after curing.

6. Roll instead of sheets

On a roll the page is as long as it needs to be — no bottom margin wasted on every sheet. Turn on cut marks and ZoroPrint prints a dotted line where each job ends.

7. Fill the strip

There are always 15–30 mm left at the end of a sheet. Keep a folder of small bestsellers (size labels, care labels, tiny logos) and use “Fill sheet” to top the film up with things you will sell anyway.