The "Too big for nesting" message is typically related to the image size exceeding the sheet size (printable area) or exceeding the set print condition, like maximum length set inside the Nest-O-Matik options in the Server Admin (Settings Tab > Server Admin > select the printer > Configure > Nest-O-Matik tab)
For example, if you set a maximal print length under the print conditions, it means that no job can be larger than that value.
If the job is larger than the maximum print length the image is rejected as "too big for nesting".
In below example any image/job exceeding 30" (Maximum print length set to 30") will be rejected as being too big (problem image is 34.9"x31").
Other common reasons are:
1) Margins either set under the Nest-O-Matik tab or printer drivers page setup.
2) Not having the Nest-O-Matik "enable automatic rotation" checked.
3) Having the loading set, to strict or a specific roll size instead of the default Free, Free versus Strict
4) In case of a cutter, also check any custom registration mark margins and potential unexpected page setup scaling (check page setup and don't go by Spooler), Cutter Tools
The following can also be tried:
- Reset Page Setup (Reset button in Page Setup)
- Try to set the "Covering Percentage" to 100% (Setting in Nest-O-Matik Server Admin section)