Check the actual rectangles rather than the count alone
A layer count is supported by the placements that fit its stated region. Check each rectangle’s origin, length, width and rotation against the same inputs used for the result. The coordinate origin is a model reference; it is not a physical loading instruction. Keep the units and axis directions with the drawing. A count copied from another deck or an arrangement with overlapping rectangles does not describe a valid solution to the current geometric problem.
For this diagnostic, assume a 1200 by 800 mm usable deck boundary, cases with a 380 by 280 mm footprint, a 20 mm gap and 10 mm clearance at each deck edge. Rotation is disabled. These are illustrative dimensions and requirements, not recommended clearances. The allowed rectangle region runs from x = 10 to 1190 and y = 10 to 790. A case must fit completely inside it, including its length and width from its origin.
Rebuild the six-case uniform candidate
The usable length is 1200 minus twice 10, or 1180 mm. With a 20 mm gap, the row count is floor((1180 + 20) / (380 + 20)) = 3. Across the deck, floor((780 + 20) / (280 + 20)) = 2. The six origins are the combinations of x = 10, 410 and 810 with y = 10 and 310. Each rectangle retains length 380 and width 280.
The rightmost case ends at x = 810 + 380 = 1190, meeting the inside boundary. The upper occupied row ends at y = 310 + 280 = 590, leaving additional unused space before y = 790. Neighboring cases along x have 410 minus (10 + 380) = 20 mm separation. Along y the separation is 310 minus (10 + 280) = 20 mm. Unused space beyond the last row is not an extra required neighbor gap.
| Placement or change | Numerical check | Diagnostic outcome |
|---|---|---|
| First case at (10,10) | Ends at (390,290) | Inside the stated boundaries |
| Second case at (410,10) | 410 − 390 = 20 mm | Meets the entered neighbor gap |
| Third case at (810,10) | 810 + 380 = 1190 | Meets the right inside boundary |
| Move second case to x = 400 | 400 − 390 = 10 mm | No overlap, but insufficient entered gap |
| Move second case to x = 380 | 380 − 390 = −10 mm | Rectangles overlap |
| Move third case to x = 830 | 830 + 380 = 1210 | Exceeds the clearance boundary |
Apply the separation test in either axis
Two axis-aligned rectangles are separated if at least one axis places one wholly before the other, with the required gap where applicable. For example, either A’s right edge plus gap is no greater than B’s left edge, or the reverse; the same alternatives apply to their top and bottom edges. Requiring separation in both axes would reject ordinary neighbors that share a row. Ignoring both axes would miss overlaps.
Check all pairs when reviewing a small pattern rather than assuming consecutive identifiers are the only neighbors. Identifiers describe placements, not a guaranteed physical adjacency order. In the example, cases in different rows are separated along y even when their x intervals match. If a reviewed drawing uses a different spacing rule, preserve that rule explicitly and confirm the selected tool represents it. Do not silently substitute a different clearance meaning.
Verify rotation against the item dimensions
With rotation disabled, every placement must keep the entered 380 by 280 orientation. When horizontal ninety-degree rotation is allowed, a rotated case has length 280 and width 380 in the coordinate axes. It remains the same case with the same vertical height. A result that changes height or swaps in a different size is not the supported footprint rotation. The model also does not describe turning the case onto another face.
Allowing geometric rotation does not establish operational permission. Check the actual package instructions before enabling it. The configuration engine arranges identical footprints; it has no handle, label, opening or support-face model. Retain any package-facing requirements separately. If identical dimensions belong to goods with different permitted directions, a single unrestricted run cannot represent all their instructions merely because the rectangles fit.
Make a coordinate review record
Write region dimensions, units, item dimensions, gap, edge clearance, rotation permission, placement count and the actual placement fields x, y, length, width and rotation. For the example retain six cases, the two row origins and three column origins. Record the pair and boundary checks that failed if a placement was manually changed. Keep the returned search status with the geometry.
Use coordinates from the calculated scenario
Use the pallet configuration calculator for the stated dimensions, gap and edge clearance. Review the resulting pattern and its coordinate information under those same inputs. The numerical illustration above is the fixed uniform candidate; a mixed search has its own placements and status. Do not label a manually reconstructed grid as the coordinates of a different returned candidate.
Finish by counting the actual rectangles and comparing their total with the reported case count. A finite mixed search may find an improved candidate without proving a maximum. Coordinate validity supports the stated two-dimensional geometry; it does not confirm carton strength, pallet rating, restraint, loading sequence or a suitable transport plan. Those decisions require the actual application evidence in addition to a valid drawing.
Reference scope
NIST length guidance supports consistent length units. The example spacing is an explicit assumption, not an instrument standard or a universal handling rule.