Polyboard: Panel Design

Within Polyboard the Structures Menu and its commands offer a powerful set of panel design features to add flexibility to your projects. They include a variety of tooling and cut out functions, adding bar materials and frameworks, creating sandwich panels and splitting individual panels into multiple materials and types.

All Videos

Edges Tooling

How to add a shape to the edge of a panel in Polyboard. This can be used to create handle cut outs, curved surfaces and other design enhancements.

Angles Tooling

How to add a shape to the corner of a panel in Polyboard. This feature is useful if for example you would like to create a curved corner to a worktop. As well as appearing in the plans, the machining of the applied shape will be available in the CNC file for automatic machining.

Inner Tooling

How to cut out a holes in your panels for cutting and machining. You can create cut throughs, pockets and inlays very easily with this parametric feature, and import your own shapes as DXF files if you wish.

Surface Split

How to split a panel into multiple panels. Once you've done this, you can add slack between each of them, add a shape to their edge, rotate them, apply hardware and change materials individually. This gives a lot of extra design flexibility for your projects.

Surface Split: Edit Individual Panels

More features of the Surface Split command, used to divide a single panel into multiple panels. This video shows you how to edit each panel independently, which is particularly useful if you want to move and resize them separately, and for extra flexibility in your design.

Thickness Split

How to split a panel's thickness into multiple panels. This is mainly used for veneered doors and other panels where you have a core material and also a decorative outer material and on other side a balancing veneer to stop warping. All materials are included in the cut list output.


How to create a frame and panel assembly. You can use bar or panel materials for the framework, you can add additional rails, apply shapes to the frame, change materials independently for each structural element and lots more. You can also apply additional configurations from the structures menu one on top of the other. This video shows one example of that, adding a second frame assembly inside the first.

Copy and Paste a Structure

Two ways to copy your panel structures across to a new panel. You can do this with any of the structures: Surface Split, Thickness Split or Inner Tooling for example. Here we copy a frame and panel assembly.

Panel Structures Library Management

How to add your own structures (frame and panel assemblies, toolings, Surface and Thickness Split etc) to the Panel Structures Library. You can then easily apply these to new projects, or use the ones we've already set up for you.


Simulate a Shaker Style Frame with the Structures Menu

You can use bar materials to create a true frame assembly. This alternative method uses Polyboard's thickness split and inner tooling features to create a cut out from a panel.

Drawer Pull Cut Outs

How to use a variety of Polyboard commands to create a cut out for a drawer pull. Options include Single Panel Fittings, Inner Tooling and Edges Tooling.

Drawer Cut Out Handles

How to create a cut out handles in a drawer front. This method uses the Inner Tooling function, creating a circular and rectangular tooling positioned side by side at the edge of the panel. A neat and fast way to create a drawer pull/handle.

Panel Structures Library Example

Alternative ways to apply a structure and manage the Panel Structures library. In this example we also edit a bar material directly to modify an associated frame and panel structure.

Thickness Split Example with Middle Framed Layer

How to set up composite panels of several layers using the Thickness Split command. In this case, we split a single panel into 3 layers of 2 solid face panels and a middle framed layer.

L Shaped Cabinet with Front Frame and Built In Doors

How to set up a L shaped corner cabinet with a solid wood front frame and built in doors. This is put together using the Assembly feature in the Structures menu, first to create the front frame, then to create a frame and panel door inside that frame.

Constant Width Parts

How to use Quick Design Panel Structure libraries to replace a panel with cross bars, specifically where each element that must have a constant width whatever the cabinet size. This is particularly useful when breaking up a panel into separate cross rails or vertical styles that are cut to specific widths.

Top Rails

How to make a base cabinet with two top rails instead of a normal top panel. Often used in kitchen design. Two methods are shown; using Surface Split command with a slack value; and using the Inner Tooling function which allows us to keep the rails a constant width even if we modify the overall cabinet width.

Sandwich Panels

How to create composite panels made up of a central framework and two pieces of sheet material.

Cutting a Panel into 5 Parts using the Surface Split Command

How to use the Surface Split feature in Polyboard to divide a panel into several parts, in the case the back panel of a cabinet. The cuts are both horizontal and vertical.

Oven Unit using the Surface Split Command

How to use the Surface Split command on the back of a cabinet to create a partially open backed cabinet for an oven unit.

Frame and Brace Door

How to design a door that consists of 2 layers, the cladding and the frame and brace. This technique incorporates many elements of the Structures menu, including Thickness Split, Surface Split, Inner Tooling and Assembly.

Metal and Wood Table

A nice demonstration of how you can combine different materials, not just wood, within your project. This table consists of metallic profiles and a wooden frame. We use the Assembly function within Structures to create the legs.

Solid Wood Drawer Sliders

Starting with a shelf and uprights with assembly details applied, it's easy to copy/paste this structure across your entire unit. This video shows you how to duplicate these framed drawer runners.

The video doesn't show the assembly process. For this, select the shelf/upright then go to the Structure menu > Assembly, and add bars to fit. You can go back and change the orientation of intermediate cross bars from 0 degrees to 90 degrees to they run side to side rather than front to back, see the image below:

Assembly details added to shelf in Polyboard

Editing Parts

How to edit the separate parts that form the outside of a cabinet.

Create a Library Element from a 3 Layer Door

Here we want to reuse the structure of a 3 layer door in other projects. You have the option of creating a Sub-Method called Assembled Pieces but these are just framed and panelled elements. As we've got a more complex 3 layer door to replicate, we can instead build an assembled feature directly from the model. Specifically, we go into the Thickness Split property and select 'Add the Structure to the Library'.