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Thursday, May 11, 2017
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How do I Use a CNC Router to Cut Out Furniture Parts
CNC routers are "computer numerical controlled"
machines that take the fine work of measuring, sawing, wood carving, planning,
drilling, cutting mortises and tennons, and even collecting dust out of the
hands of the carpenter and put it into the processors, planers, drill bits, and
other fiddly bits of the computer and router machine. What can be achieved in
terms of project design, time savings, and labor savings with a CNC wood router
is nothing short of stunning. But even more stunning is that these computer /
router machines are now affordable for use in the home shop.
Cutting a narrow triangle-shaped opening with power and/or hand
tools is anything but simple. Cutting parts with precise details is a task well
suited for digital woodworking and CNC Routers.
How I use a CNC Router: Part Two
In the previous post, I gave an overall explanation of the
process that I use to make furniture parts with a combination of various power
tools and hand tools. Essentially, it’s a hybrid process of power and hand
tools that many other professional and hobbyist woodworkers use. The goal is
consistency and accuracy. I mill and square up materials with jointers, planers
and saws. Then, I rough cut and final shape parts to my patterns.
Stock Preparation
So, how does the process change when
you use a CNC Router to cut out your parts? For me at least, some things are
the same. I still prepare my stock with the same tools as before with saws,
jointers and planers. Getting your boards flat and square is even more critical
when using a CNC Router. You want the boards you’re going to CNC Router very
flat. From this point on, everything changes.
Below is a simple example of the CNC Router
doing what it does well: accurate part cutting. In this example, we’re not
cutting out a complete part, just a shape in the middle of a board. A
long, thin triangle. As simple as it looks, I’ve had to make this exact cut
many times. It’s been difficult with any combination of power tools and hand
tools. The red triangle in the drawing below shows you the area I need to
remove.
A Challenging Cut for Woodworkers
Here’s the problem: The triangle is
very narrow. It’s about 2-1/2” wide at the top and tapers down over 9” to a
sharp point. It might seem simple but in practice it’s been a
difficult detail to cut out accurately. I’ve tried all the woodworking processes
that you’d expect. The most successful technique has been to drill holes in the
corners, then jig saw or scroll saw out the triangle. So far, I’ve been unhappy
with the results. Even holding a jigsaw to a guide, the walls of the triangle
are not perfectly straight and smooth. So, after rough cutting, I set up a
two-step shaping process with the pattern to get the walls straight.
But, we’re just getting started. The sharp end of the triangle keeps it
challenging. Time for rasps, files and lots of sanding in a difficult-to-access
area before the job is done. After a lot of time-consuming work, I’ve never
been completely happy with the quality of the results. This job is all about
precision. That makes it a perfect task for a CNC Router.
First Draw the Part, Then Cut It
After drawing the board and the
triangle in CAD and then programming the CNC Router with CAM software to
make the cut, I place the board on the bed of the CNC Router, align it, clamp
it tightly and begin. I cut my way down in steps to the full 1” depth of the
board just as you’d do with a router. Small connecting pieces of wood at the
bottom of the cut called “tabs” or “bridges” are left to keep the triangle just
slightly attached to the main board. That keeps it from rattling around during
the last pass and potentially damaging the part.
You can see the tabs being machined in
the video below when the CNC Router pauses, rises up and then drops down.
Total time to cut the triangle opening: 116 seconds. The results are perfect.
When you add in the time for changing boards and clean up, eight boards
were completed in 20 minutes.
Sometimes
a small detail is a big challenge. Cutting this narrow triangle out of a board
is particularly difficult using other woodworking techniques. With a CNC Router it’s done quickly and accurately.
Though this triangle is only a simple
example, it should give you an idea of how accurately and quickly a CNC router
can machine parts. If we were cutting a complete part with any combination of
curves or shape, there’s a bit more involved but in general, the process is
pretty much the same.
As I said previously, a CNC Router can
do many things. Certainly, it does some tasks better than others. And, as
always, some tasks are better left to hand or power tools. Accurate part
cutting just happens to be one woodworking task a CNC Router does very
well.
Use CNC Router Hybrid Techniques to Make Furniture Parts
Furniture making involves making a lot
of parts. Stacks of dining chair parts are made by first rough cutting stock.
Then they are shaped with patterns on a shaper.
How I Make Parts Using Hybrid Woodworking CNC Router Techniques
In previous posts, I wrote about what
led me to get my own CNC Router. Now that I have one, a couple of questions
come up. What’s changed in how I do my work? What do I do with a CNC Router? In
the next two posts, I’ll explain how I previously made furniture using a
combination of power and hand tools and how I’m now using a CNC Router to help
me accomplish the same tasks.
First up. Making parts. Outside of
joinery, making parts is a furniture maker’s primary woodworking task. Since my
clients tend to order several pieces that means lots of parts to make. Because
I make a living at it, I need to be efficient with my time and the parts I
produce have to be accurate. Like many woodworkers I take a hybrid approach and
use power tools where appropriate. Saws for rough cutting. Jointers and planers
to square and thickness material. In the right situation, hand tools are used
which often are a better, faster and more efficient solution than power tools.
Now it’s time to cut the parts that
aren’t going to end up rectangular. Since I make very few things that are
square that means that most parts need more work. I use various techniques to
get my furniture parts into their final shape. But, my main method is using
patterns and shaping.
First, I rough cut the part with a bandsaw
to just outside a line that is drawn around a pattern. For shaping, I use my
favorite shaping jig that adapts to the part instead of the other way around. I
wrote about it a few years ago for another woodworking magazine. Patterns and
rough cut boards are clamped to the jig then it’s off to my two shapers to
shape parts.
My shaping jig is really a jig system based on a 3 1/2″ grid layout. A standardized top clamp section is attached to
various bases and adjusted to position and hold the part optimally. As a
result, I can shape furniture parts of any size or shape from small to 8′ long.
Lots and Lots of Shaping
To be honest, I really like shaping.
That may make me unusual. Most woodworkers don’t like doing it because it’s a
justifiably intimidating process that really keeps you on your toes. However,
armed with a great jig the task is faster, safer and much more pleasant to do.
One of the reasons I like doing it is that when you’re done, a perfectly shaped
part is the reward.
Unfortunately, shaping is not a
one-step process. There’s a lot of added detail and fussiness along the way to
a completed part. A key issue in using a shaper properly and safely is that
excess has to be left at the entry and exit points to be later cleaned up with
a small plane or a sander. After that, you sand to blend. The entire process of
pattern shaping results in a very good part. It’s not a perfect part, but it’s
close. And, then there’s the issue of time. Shaping is time-consuming. I
regularly spend several days at a time doing it.
If it’s precision you’re after, then
digital woodworking offers clear advantages when it comes to part making.
Potentially, CNC Routers give you perfection where you need it the most. Part
making is one of the best uses of a CNC router in a woodworking workshop.
Because they have a high level of precision and repeatability and they don’t
care if they’re cutting straight, around a curve, in a zig zag or any kind of
shape you come up with, it makes CNC Routers an ideal tool to for cutting
parts.
I’ll give you a simple example of how I
use a CNC Router to cut a part in my next post.
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