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Tricky Veneer, substrate, inlay question

3/10/14       
sol

Hello All,
Have some questions about a tricky project. Im looking to inlay 1800 1.5" square pieces of pine in the face of a sheet of 3/4 plywood (or veneered mdf), and am concerned about warping and durability of mdf vs. plywood. The inlays will be CNC routed to a depth of 1/8", thus removing more than 75% of the face material of my panel. Inlays would be glued in with titebond, and later routed flat.

I am mainly concerned with the panel remaining flat once I begin introducing all of these inlays, and with the panel remaining flat in the long run, as this is going to be a stand-alone panel, shown as a sculpture.

Im wondering if anyone can recommend a specific type of mdf (trupan, hi density, etc?) , or if anyone would recommend plywood.

Thanks for any input!

Attached are a couple of images showing the densities of inlays and the inlay material...


View higher quality, full size image (1087 X 629)

3/10/14       #2: Tricky Veneer, substrate, inlay que ...
Charles Wright  Member

Website: http://www.northcreekwoodworks.com


I DOUBT THAT THING WILL EVER STAY FLAT. ONCE YOU REMOVE AND REPLACE PLUS MILL FLAT, THERE IS NO BALANCE. JUST SAY'IN

3/11/14       #3: Tricky Veneer, substrate, inlay que ...
Rich C.

I would build a thin torsion box instead of using a single sheet. CNC routing flat will really be an issue if you are on top of thin veneer. You'll definitely have to stay off the veneer while routing flat. I suspect that will have to be more hand work than machining. Rounding all those corners on the pine blocks is also going to be a pain to match the CNC router bit. Good luck!

3/11/14       #4: Tricky Veneer, substrate, inlay que ...
sol

thanks for the suggestions and cautions. Its important that the thickness of the panel remain below 1", so I think a torsion box is not an option. Had thought about a plexi core, or some other kind of stable dense plastic, but can imagine that will open a whole can of worms with adhesive options. Regarding corners, Im actually squaring the inlay holes themselves, with a 4-cutter corner chisel jig that I made up, and then dropping the square inlays right in, to about a 1/8th" depth.

Im still looking for any suggestions for a panel material… have not settled on MDF but my tests so far are looking OK.

Thanks for any input!
All the best

3/12/14       #5: Tricky Veneer, substrate, inlay que ...
Long dong silver

Look into aluminum honeycomb panels. There is a place here in Oakland, ca. that makes them

3/15/14       #6: Tricky Veneer, substrate, inlay que ...
Rich G

I would recommend MDF. Balance construction is the key here. After you route all your squares try sanding off about the same thickness off the back and glueing 1/8" thick veneer on the back or whatever the thickness is of your pine squares. I would also cold press this panel. Or do the reverse, sand off the back first and then route your squares.


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