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Machining Scallops or Flutes into MDF Panels
Question
Forum Responses
 Click here for higher quality, full size image  Click here for higher quality, full size image From contributor D: To the original questioner: Could you post a picture? Contributor T, how much will your panels warp after you machine the waves? From the original questioner: Thank you for your posts. A drawing to show what panel I am after. I will need two panels, 20" x 32" (rough, not final size) out of standard 3/4" MDF. The coves are 2" wide with a 1/16-" flat between. While your organic cuttings are spectacular and I will show them to the designer, the straight rows of coves correspond to other elements in the room.  Click here for higher quality, full size image From contributor D: Your drawing is more of what I suspected from your description. This should be fairly simple for any out there with CNC capabilities. You do know cuts like that in MDF will warp the sheet. From the original questioner: Thanks for the input. The cove panels will be mounted to a solid substrate so I don't expect the bowing to affect the final profile. Of course, you never know. From contributor T: "How much will your panels warp after you machine the waves?" 1/8 - 1/4 on 4" to 5" of outside edges. The middle stays flat. Nothing Liquid Nails can't handle. It took some time and a lot of dead ends but we got the process down. Material, tooling, and tool path strategy is key to keeping it flat. The hard part was the hairs that lift in the MDF when painted. Now it's relatively easy considering what we went through to refine the process.
From contributor J: You can cut those on a table saw with a skewed fence. Just fiddle with your fence angle and blade depth to get the width and depth required. For two panels, hardly worth the effort and tooling for CNC. Not to mention shipping and related damage. Might give it a look. From contributor D: You are right. If someone wanted to have this made for a one off project it could get expensive. Luckily, I've got a cove bit sitting on the shelf that's 2.5" across. I use it for some of the cabinetmakers that come by my shop for specialty kicks and what not. The bigger issue is the mess involved. That bugger kicks the chips and dust. I'm setting up to run the bit today for some straights and I'll cut a sample of what the questioner's drawing shows. From contributor D: Don't tell the boss ;) Yes, it will be a little fuzzy.  Click here for higher quality, full size image From contributor T: Looks great! It does get messy. We're dumping 12-15 55 gallon drums of MDF dust a day. Would you like to add information to this article? Interested in writing or submitting an article? Have a question about this article? Have you reviewed the related Knowledge Base areas below? 
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