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Maximising board usage in carpentry – Insights from a pro

Sep 27, 2024 | News

In carpentry, efficient material usage is a critical skill that can make or break a project. When working with versatile materials like MDF and Particleboard, knowing how to maximise board usage, saves both time and money and ensures your work is polished and professional. 

We spoke to seasoned carpenter and master craftsman Paul de Klerk from Fine Tune Interiors to gain expert insights on getting the most out of these materials. 
Read our previous article about the latest update with Flipping Johannesburg and Moremi Kitchens. You might be happy to know that Paul has worked alongside Steven Baron, of Flipping Johannesburg fame, to help with the video renovations and renovations within Steve’s home.

Being able to speak with Paul de Klerk was indeed insightful. Here’s what he had to share…

1. Planning and measurement – The key to efficiency

The planning stage is crucial before making the first cut. Proper measurements ensure minimal waste and optimal use of each board.

“One of the most common mistakes I see in carpentry is rushing the planning phase,” says De Klerk. “You need to think carefully about the size of each piece you need and how to maximise the material available. Especially when working with materials like MDF, it’s important to map out every cut in advance.”

Using tools like CAD software or even hand-drawn templates can help you visualise the layout on your board and avoid costly mistakes.

A cutting list, also referred to as a bill of materials or schedule of materials, outlines every part needed to construct a project, along with crucial details such as quantity, material, and dimensions (thickness, width and length).

While creating a cutting list by hand can be time-consuming and error-prone, using cutting list software is a more efficient solution that enhances both accuracy and productivity. Another major benefit of using cutting list software is that it allows for instant recalculations should you decide to make any design changes. The instant recalculation will once again ensure that you optimise material use, thereby reducing waste – a significant cost factor for any woodworking business – be it private or commercial.

The Importance of Cutting List Software

Cutting list software automates the creation of cutting plans and helps streamline the production process. Here are three examples of cutting list platforms that can significantly improve efficiency:

  1. MaxCut
    • Overview: MaxCut is a comprehensive cut list optimisation software designed for cabinetry and woodworking. It automates the creation of cutting plans, ensuring minimal waste and accurate cost estimates. MaxCut is user-friendly and supports features like bulk material changes, professional quotes, and detailed job reports.
    • How-to: Input your panel sizes and materials, and then, at the press of a button, you can generate optimal cutting diagrams. Customise layouts for material efficiency or cutting speed. Easily modify cabinet attributes and print labels for organised workflows. MaxCut also allows accurate cost estimation based on materials and job specifications.
  1. PolyBoard
    • Overview: PolyBoard is a parametric design-to-manufacturing software that simplifies the process of managing cutting lists. Instead of manually drawing parts, you can size the carcass and position components like shelves and doors. This software dynamically updates the cutting list with every project adjustment.
    • How-to: After setting the dimensions and adding components, you’ll instantly generate a cut list, a 3D view, and even CNC files. If design changes are needed, simply update the dimensions, and the cut list will automatically adjust to the new specifications.
  1. CutList Plus FX
    • Overview: CutList Plus FX is a versatile software used for cabinet-making and woodworking. It helps you create cut lists and generates layouts for cutting parts out of sheet materials. The software also includes cost-estimating features to keep projects on budget.
    • How-to: You can enter your project’s part dimensions into the software, and it will generate the optimal cutting layout. The program even considers material costs and allows you to customise your settings based on available stock and project requirements.

When utilising cutting list software, there really isn’t a downside. You save valuable time, minimise errors, and ensure efficient material use, all of which add up to better productivity and cost savings.

Image source: https://www.youtube.com/watch?v=I-JL8yhg-Ls

2. Choosing the right finish for the job

Innovus Decorative Products® offers a variety of finishes and decors. 

Finishes:

There are five different finishes, being Silhouette, Textured, Alpine, Spirit, and Stucco. Each finish has a distinct look and feel, making it suitable for different applications.

“The Innovus range is fantastic for customisation,” says De Klerk. “For example, if I’m working on a modern interior, I might go for the Silhouette finish with its deep-matte wood grain, which looks incredibly high-end. For a rustic look, the Spirit finish brings out the core character of wood grains.” 

Knowing which finish works best for your project adds to the aesthetics and helps to both maximise the board’s potential and the visual appeal of the space you’re working in.

Decor:

Our exciting array of decors includes exclusive solutions in melamine-faced boards and laminates, helping you find the right colour, the ideal finish and the perfect pattern.

Choose from our three inspiring options: 

  • Fantasies: 10 textured, rocky, or ceramic-inspired finishes to elevate the creativity and aesthetic of your spaces.
  • Woodgrains: 27 wood decors and exclusive finishes to add charm and sophistication to any space or furniture.
  • Unicolours: 8 options to choose from to achieve the perfect shade to complement your vision. 

3. Cutting techniques – Precision matters

How you cut your board can significantly impact the efficiency of material use. With MDF and Particleboard, precision is critical. De Klerk recommends always using a sharp blade and maintaining clean, consistent cuts to avoid damaging the surface.

Image source: https://www.youtube.com/c/FlippingJohannesburg

“When cutting MDF or Innovus boards, you want to minimise the number of cuts,” says De Klerk. “Try to cut as much as possible from a single board to prevent waste. Also, MDF can sometimes chip along the edges, so using a fine-tooth blade or even pre-scoring the cut lines can prevent that.”

4. Using the right tools for the job

Using the right tools can make a big difference in how efficiently you use your boards. 

Image source:  https://www.youtube.com/c/FlippingJohannesburg

“With the quality of materials like Innovus, it’s worth investing in tools that offer precision,” De Klerk explains. “A track saw allows you to make long, straight cuts with minimal waste, while a table saw is perfect for repetitive pieces that need consistency.”

Tools like jigs or guides can also ensure that your cuts are accurate and repeatable.

5. Avoiding waste with proper handling

Particleboard and MDF are durable materials that can be damaged if improperly handled. De Klerk stresses the importance of storing boards flat and using proper lifting techniques to avoid bending or damaging the edges.

He goes on to say, “I always tell my team that how you handle the board is just as important as how you cut it. Keeping the boards flat prevents warping, and when you’re moving them around, make sure you don’t drag them across the ground or lean them against walls for too long. Even a small dent can ruin the final product.”

6. Making use of offcuts

Offcuts are often seen as waste in carpentry, but De Klerk believes they can be turned into valuable pieces for future projects. With Innovus Decorative Products®, offcuts can be used for minor decorative elements or custom fittings.

Image source: https://www.youtube.com/c/FlippingJohannesburg

“Never throw away your offcuts until the project is fully done,” De Klerk advises. “I’ve found that offcuts from larger boards are perfect for drawer bottoms, shelving, or even test pieces for staining or finishing. Innovus Decorative Products® has such a wide range of finishes that you can always find a creative way to use the offcuts.”

7. Sustainability through smart material use

Maximising board usage is not just about efficiency and cost savings, it’s also about sustainability. Innovus Decorative Products® are designed to be versatile and eco-friendly, which makes thoughtful use of these boards, a step towards more sustainable carpentry practices.

“The more efficient you are with your board usage, the less material ends up in the bin,” De Klerk notes. “It’s important to remember that as craftsmen, we have a responsibility to minimise waste and make environmentally-conscious choices. Choosing Innovus Decorative Products® offers a great solution because they’re built to last and thus reduce the need for replacements.”

Maximising board usage when working with MDF and Innovus Decorative Products® is essential to elevate any carpentry project. Through careful planning, precision cutting, and thoughtful material use, high-quality results can be achieved while minimising waste.

“The best carpenters are the ones who know how to get the most out of their materials. By understanding the strengths of MDF and Innovus Decorative Products® and using them strategically, you can take your craftsmanship to the next level”, decares De Klerk.

With these expert tips, you’ll be well on your way to mastering the art of carpentry while maximising your materials for efficient, sustainable, and beautiful results.

Thank you to Paul de Klerk for giving us a sneak peek into his design process. We truly appreciate working alongside professionals like him and would love to collaborate again in the future.

Get in touch with Paul and transform your home interior with trusted experts.

Contact:

Cell: 078 128 8700

Email: paulbdk76@gmail.com

Facebook: https://www.facebook.com/p/Fine-Tune-Interiors-100065324508554/

Take a look at our various distributors and affiliates:

The Building Centre, The Kitchen Specialists Association, The Green Building Council, and The African Institute of the Interior Design Professions

For more information on our wood-based decorative panels and services, visit us at https://sonaearauco.co.za/