Probably would save on weight, but without having everything stuck on nice neat sheets it might make the package actually end up bigger and most shipping companies charge dimensionally as well as on weight.
The size difference, if any, would be miminal at worst. I am sure her experts out there would make short work of such a issue.
Popping out 1000 pieces would also add alot of labor to the production end of things.
Again miminal. The cutter was to cut out all the pieces pull out the frame and slide the bits into a box. Again the experts would have a better explanation of the process.
And adding to the labor. More sales helps to offset production costs.
What I am thinking in my head to make the changes all depends on what the factory floor and set up looks like.
Grimm