too big to ship.
cut this week, ten miles away.

a round cutter cannot cut a sharp inside corner. every inside corner comes out with a radius of half the cutter — 1/8in with our standard 1/4in end mill. you have three choices per shape: leave them rounded, add relief cuts so a square part still seats, or pay to have them squared by hand after machining. the drawing shows you exactly what each one does before you order.

we hold ±1/16in in every dimension — x, y and depth. depth is measured down from the top face, so it also carries however flat the sheet sits and how much its thickness varies. what we can tell you exactly is the geometry: inside corners come out at 1/8in, nothing narrower than the 1/4in cutter can be cut, and round holes under 1/4in are drilled rather than milled. sheet stock also moves with humidity, so a part cut to size in a dry shop can measure differently a week later.

nothing narrower than the cutter, so 1/4in is the floor for a slot or an internal web. round holes smaller than that get drilled instead, which is why a small circle switches itself to a drill when you upload it. the configurator warns you when a feature is narrower than the cutter rather than letting you order something we cannot make.

a pocket has to leave at least 1/8in of material under it, so the maximum is the material thickness minus 1/8in. cut any closer to the far face and the floor blows out, and on thin stock the part flexes off the spoilboard while it is being cut. the depth field tells you the ceiling for whatever material you picked. if you want it all the way through, choose cut all the way through instead.

usually, yes. a part cut all the way through has to stay put until the cut finishes, so we leave small tabs holding it to the sheet and cut them free afterwards. we sand them flush, but on a visible edge you may still see or feel where they were — the grain around a tab can read slightly differently even once it is level. if a particular edge has to be perfect, say so on a custom job and we will place the tabs somewhere that does not matter, or finish that edge by hand.

up to a full 48 × 96in sheet, and baltic birch comes in 48 × 60in. the machine bed is larger than any sheet we stock, so the sheet is the limit rather than the router. a part bigger than the sheet you picked is rejected at quote rather than at the saw.

plenty of free options. inkscape is the easiest start if you are drawing rather than engineering, and we take SVG directly so you do not have to convert anything. librecad and qcad's community edition are free 2D CAD programs that work natively in DXF. freecad does it too if you are already modelling in 3D. onshape runs in a browser and is free as long as your documents are public, which is worth knowing before you put client work in it. if you are willing to pay for something, lightburn is worth a look — it is sold for laser cutting but it is a genuinely good vector drawing and editing tool, it exports DXF, and there is a free trial to see if you get on with it. whatever you use, draw at real size and we will confirm the scale with you on import.

DXF or SVG, one part per file — a single outer profile plus whatever holes, pockets and slots are inside it. we always ask you to confirm the scale on import, for both formats: DXF headers are unreliable about units and SVG user units are ambiguous, and a file read at the wrong scale is the most expensive mistake either of us can make.

5 business days on stocked material, from the moment you order. 4 lb sign foam 1" runs longer at 20 days. orders are held at a $45 minimum, so small parts all land at the same price until the quantity carries it past that.