The new CardCutter add-on for Blender converts texture masks into usable 3D geometry for Nanite-based projects in Unreal Engine 5. Created by developer Philipp Russo, the tool simplifies building game-ready foliage and decals by generating optimised meshes directly from source textures.
CardCutter operates as a geometry generation tool that converts 2D texture data, either alpha-masked colour images or greyscale masks, into fully triangulated 3D meshes suitable for Nanite rendering. The add-on functions within Blender’s Python API and supports Blender 4.0 or higher. According to the developer, the geometry output is designed to conform to Nanite’s mesh constraints, favouring dense, evenly distributed triangles over traditional quad-based topologies.
Each processed mask is interpreted as a binary image, with the alpha threshold defining the polygon contour. The tool applies an internal vectorisation step to trace the boundary of the visible region, followed by a polygon simplification algorithm to remove redundant vertices. It then uses a relaxation solver to re-distribute triangle density uniformly across the surface, creating stable topology for Nanite’s internal micro-polygon clustering.
Automatic atlas splitting
When the user provides a texture atlas (for example, a leaf sheet), CardCutter automatically detects discrete masked regions using connected-component labelling. Each detected region becomes a separate mesh object in Blender’s scene graph. This removes the need for manual cutting or polygon mask painting, which is typically required in foliage production. Each region retains its local UV coordinates, preserving the original texture mapping from the atlas. The output meshes can be exported directly as FBX or glTF, maintaining UV alignment and pivot orientation suitable for Unreal Engine import.
Geometry presets for performance tiers
CardCutter offers several density presets: Low, Medium, and High, which define the target number of triangles per pixel area. The lower settings generate lightweight meshes for background vegetation, while the higher settings produce Nanite-ready geometry that benefits from Unreal’s automatic cluster streaming.
The generated meshes are particularly intended for organic and irregular silhouettes like leaves, vines, ivy, ferns, but the developer also notes suitable use cases in flat debris, stickers, posters, and paper scraps, where alpha planes normally create overdraw problems.
In Nanite rendering, alpha cutouts are computationally expensive since masked fragments are still rasterised. By converting them into actual geometry, CardCutter removes the transparency pass entirely, allowing the GPU to perform visibility culling at the triangle level. This is beneficial for scenes with dense foliage or decal overlays.
Export workflow and integration
Meshes generated by CardCutter can be exported directly from Blender using Unreal’s standard FBX pipeline. The add-on does not alter material data; instead, it preserves UV maps for external shading setups. Unreal users can apply the same texture as an opacity mask or base colour without modification.
CardCutter also supports consistent vertex orientation to avoid flipped normals during export. According to the developer, all geometry is manifold and suitable for Nanite import without further cleanup, though it may require triangulation if the user modifies topology post-generation.
Pricing and licensing
CardCutter is distributed via Gumroad. The Individual/Freelance licence costs €12 and includes full functionality, updates, and one user seat. The Studio/Enterprise licence, priced at €50, allows unlimited installations within one facility and provides priority support for pipeline integration. Both include lifetime updates and are maintained by Philipp Russo under The Triangle Forge label.
Technical limitations and notes
At the time of publication, CardCutter is compatible exclusively with Blender 4.0 or newer. The add-on does not currently support real-time texture-to-mesh previews or batch automation through the command line.
Users should test export consistency when integrating the tool into complex Unreal foliage systems that depend on hierarchical instancing or runtime material overrides. The add-on outputs static geometry only, without procedural modifiers or animation rigs.
