Physics Simulator for Bin Packing

This precision machine shop produces thousands of irregularly-shaped metal parts daily. Workers packed bins by instinct — often underfilling to avoid jams or overfilling and causing damage. About 20% of bin capacity went unused, which meant more bins, more shipments, and unreliable inventory forecasts.

We built a physics engine that simulates gravity, collision, and settling behavior for any part shape. It takes CAD models, runs thousands of virtual packing iterations, and shows workers exactly how to load each bin. The whole process takes seconds.

Bin utilization went from roughly 65% to over 85%. The shop ships less often, uses less packaging, and can actually predict how many bins a production run needs. What used to be hours of trial-and-error is now a quick simulation.