The following article focuses on common cabinet making problems that workshops may come across. Through our experience, and communication with industry professionals, we have developed this as a guide for cabinet makers to improve their practices and complete quality work when faced with a range of common manufacturing problems.
We address common problems manufacturers face with materials, cutting practices, CNC setups and installation work
Material problems
Poorly cured manufactured board
Manufactured boards, such as particle board and MDF, are made by bonding wood fibers and particles, using a resin or an adhesive. Heat and pressure are applied to cure the adhesive into a solid to create the manufactured board.
If this process is not completed properly, defects can be spotted in the materials and are commonly seen as follows:
- Crumbliness or chipping when machining
- Excessive warping or bowing
- Inconsistent board thicknesses
- Delamination (for laminated boards)
Usually, the best solution for these problems is to contact and notify the manufacturer.
When the material is first unstrapped, it is good practice to feel for heat in the material. If the material has warmth, the resting process may not have sat the required length of time.
Straight away strap the pack back together and allow it to rest for another few days, while also notifying the manufacturer.
Poor quality cuts
When cutting material with either a panel saw or a drop saw, using the correct blade is critical for a quality cut. Without it, burns, chips and waves can be caused across the cut.
The following guidelines can be considered for different material cutting actions, please confirm individual requirements with board manufacturers and suppliers:
| Material | Blade type | Teeth (for a 10″/254mm blade) | Tips |
|---|---|---|---|
| Plywood | Alternate top bevel | 60-80 | Use a sharp blade and painters tape for a clean cut |
| Melamine | Triple chip grind | 80-100 | Cut face down on circular saws and use painters tape |
| MDF | Carbide tipped | 60-80 | Cut slowly |
| Hardwood (cross cutting) | Crosscut alternate top bevel | 60-80 | Support ends (backup cuts) to prevent chip out |
| Hardwood (ripping) | Rip blade | 24-30 | Feed slowly with the grain |
| Softwood | Combination | 40-50 | Cut slowly and tape if required (depending on timber species) |
| Veneered boards | High tooth count alternate top bevel | 80-100 | Cuts should be face up on table saws and down on circular saws, cover cuts with painters tape |
CNC problems and solutions
Making sacrificial (spoil) boards from packing sheets
Recycling is the process of transforming waste into new materials and products. In many workshops, protective packing sheets from new material shipments are repurposed as sacrificial boards for CNC machinery.
Completing this process reuses material, although it comes with its own problems that require processing. Examples include the following:
- Packing sheets are commonly too small for sacrificial boards; this can be rectified by joining multiple packing sheets together and cutting the overall boards to the correct size; these should be glued together, biscuit joints allow for increased strength and aligned joints
- Packing sheets are often factory seconds and may have thickness inconsistencies; to address this, it’s recommended to skim both sides of the sheet using a CNC machine; this process levels the surface and ensures consistent thickness throughout the material
- After cutting and machining packing sheets, they are inclined to take in moisture and create bowing across the material; sealing the board is a good practice, you can use a paint brush and PVA glue to seal all of the edges of the board
CNC maintenance schedule
CNC machinery is like all machinery, parts wear over time which can lead to breakdowns and excessive machine down time.
The recommended solution is to keep a running maintenance log to monitor when parts are wearing out. See the following example:
Dust and woodchip buildup
Excess dust and woodchips are usually the result of inadequate dust extraction. Firstly this could be the result of an underpowered dust extraction system, cabinet makers should confirm the required specifications for the machinery they are operating.
Additionally, dust extractors require maintenance as other machinery does. Again, include this in a maintenance log, for example filter cleaning and replacement, to maintain optimum dust extraction capabilities.
Installation problems and poor framing
Walls and floors that are out of plumb/square can create problems when measuring or installing on site. These problems can lead to excessive material use and increase site installation times, even forcing additional on site trips extending the total project timeline.
There are multiple tools that have been developed to counter these problems, both in measuring and installing. Proper measuring allows for a cabinet maker to be prepared for challenges on site, while installation practices work around and with the practical problems.
Measuring
Measuring, scanning and documenting sites with modern laser equipment can help woodworkers understand the challenges they will face from a project.
Scanned sites can be used as data within design software and machinery to avoid problems before installation processes begin. An example of a scanning system is the Leica BLK3D.
Installation
Many tools have been developed that allow woodworkers to manipulate projects on site to work with inconsistencies. Standard tools such as saws, planers and scribes work with common levelling problems, and more advanced tools such as the SHAPER ORIGIN are available to automate some of these processes.
The SHAPER ORIGIN allows for scans to bring digital precision and CNC operations to site with a handheld machine, opening endless possibilities for modification and production on the road. Great when projects don’t go exactly to plan!
Keep learning…
Cabinet makers continually face a range of difficult project challenges, but over time we’ve seen the rise of effective industry practices to address them.
By sharing knowledge and insights, we can all contribute to the continued improvement of the trade. We invite you to share your thoughts on our ideas and let us know how you tackle common industry issues.
You can also click here to learn more about PolyBoard, our software for cabinet making.
