Define the usable rectangle
The planner reserves the specified rail width on all four sides of the panel. It then places boards in a single fixed orientation with the entered gap between adjacent boards. Width and height describe the rectangular envelope; the model does not nest irregular outlines.
The same rail value on every edge is a simplifying assumption. Real panels may need different handling margins, tooling strips, coupons or carrier features. Include those requirements in the final panel drawing.
Check the arithmetic with an example
A 250 × 200 mm panel with 5 mm rails leaves a 240 × 190 mm interior. For boards measuring 50 × 40 mm and 2 mm gaps, four columns occupy 206 mm and four rows occupy 166 mm. The arrangement therefore contains 16 boards.
The individual board area is 2,000 mm² and the total panel area is 50,000 mm². Sixteen boards occupy 32,000 mm², giving 64% board-area utilization. This percentage is geometric and does not predict fabrication yield or pricing.
| Example input | Value |
|---|---|
| Panel | 250 × 200 mm |
| Board envelope | 50 × 40 mm |
| Rails / gap | 5 mm / 2 mm |
| Fixed-orientation result | 4 × 4 = 16 boards |
| Board-area utilization | 64% |
Compare orientations deliberately
Swap board width and height to test a rotated arrangement. The tool does not automatically mix orientations or optimize irregular nesting. A mathematically denser layout may be less suitable for component placement, reflow, testing or depanelization.
A zero-board result means that the chosen rectangle does not fit within the available area under this model. Review the units, rails and board envelope before considering a different panel.
Turn the layout into an assembly-ready panel
Agree whether separation uses routing, scoring or another defined process. Specify tabs, breakaway features, component clearances, fiducials, tooling holes and the handling strategy. Consider tall or overhanging components and the stress introduced during separation.
The panel planner does not verify these features or reserve space for coupons. A final drawing should identify the approved dimensions and tolerances, board orientation, revision and any special handling restrictions.