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1 Piece routed MDF door - shaker style


I am new to CNC and looking for an advice to make 1 piece routed mdf door (shaker style) using Biesse cnc router. Pocket is 1/4" Deep. What kind of router bit do I need? How many pass do I need to get good finish? How long does it take to cut one 4' x 8' sheet. I am also wondering if it will be feasible for me to make my own doors with good quality or outsource it. How are you guys doing it?

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7/6/18       #2: 1 Piece routed MDF door - shaker st ...
Dropout Member

2" diamond, then 3/8 or 1/2 on the perimeter, then 1/8 on the perimeter.

It's very doable. Thousands of these doors are made every day.

The hard part is balancing the depth of the three tools with the tendency of the MDF to raise off the table as you cut the pockets. Melamine backed MDF helps. Some have said that you should cut the outside dimension first (not all the way through) to avoid that.

7/6/18       #3: 1 Piece routed MDF door - shaker st ...

Ditto on MDF bending when you cut that front pocket. For doors bigger than 24" wide or tall, I go through the trouble of first cutting a 1/8" deep pocket on the back side of the doors, and it seems to mitigate the warp somewhat. Not sure what software you're using, but Cabinet Vision makes it easy to do this. I use a 1-1/2 diameter mini flycutter from Amana to hog out most of the pocket, then work the pocket's perimeter with a 1/4" downshear, then sharpen the corners with a 1/16" downshear. I prefer sharp inside corners because most of our doors get applied moulding of some kind, and a 1/32" radius on the inside is sharp enough for the moulding miter.

Time per sheet depends on cutters. I do a lot of back-side cutting: door hinges, drawer adjuster holes and back-routing pockets for big doors. With front and back processing it can add up to 20ish min per sheet. It's still considerably faster and more accurate than stick-built shaker doors.

7/10/18       #4: 1 Piece routed MDF door - shaker st ...
saturnfan Member

I contacted a local sales guy and he advised me to buy Royce Ayr - Diamond pocketing tool, Vortex upcut Bottom Surfacing Cutter 3/8" and 1/8".

I am planning to use mdf with melamine back but I am concerned that mdf will raise off the table with upcut router bit. What do you guys think?
Thanks a lot.

7/10/18       #5: 1 Piece routed MDF door - shaker st ...

Depends on the strength of your hold-down vacuum, and also on the order in which you cut. Cut all the pockets first, then the perimeter and you should be ok.

7/11/18       #6: 1 Piece routed MDF door - shaker st ...
saturnfan Member

What's the purpose of using 1/4" downcut and then again 1/16" downcut?

7/11/18       #7: 1 Piece routed MDF door - shaker st ...

It's to sharpen the inside corners quickly. The area my 1-1/4 cutter misses is too big for a 1/16 to quickly route out. The 1/4 bit makes quick work of it and makes less area for the 1/16 to finish the job.

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