Laser cut MDF parts - delivered same day, or your money back.^*

MDF is a specially engineered wood that stands for Medium-Density Fiberboard, and as the name suggests, is constructed by grinding up wood fibers and then bonding them together using glue. The resulting material has uniform strength, is highly efficient in its use of scrap wood from other machining processes, and is very easy to shape. Unlike most other wood products, MDF is more similar to cardboard in that it expands when wet and doesn’t snap or shatter when bent. Instead, MDF almost has a soft texture that easily creates dust when broken, and it is this texture that means MDF cannot easily be cut with serrated saws with large teeth. The suitability for use with machinery combined with its high yield and strength makes it popular in furniture and wooden enclosures.

Laser cutters are an ideal method for cutting MDF sheets as MDF is prone to tearing if cut with serrated blades (this only happens with slow cutting speeds and low TPIs). As laser cutters use vaporisation for cutting materials, they do not damage the fiber structure and create clean-cut edges. However, laser cut edges have a black burnt color which results from the laser burning capabilities. Another advantage to using laser cutters with MDF is that mechanical methods of cutting create large amounts of fibrous dust. As such, the use of a laser cutter can reduce the number of airborne fibers and is, therefore, safer for the environment.

As MDF burns when exposed to intense laser beams it can easily be engraved, and the use of light colors results in a contrast between an engraved design and the base material. Furthermore, engraving and cutting are done in the same laser setup meaning that designs are faster to produce compared to CNCs. Engraved MDF does not result in a major height difference between the base material and the engraving design, but the burning effect creates a design that is virtually impossible to remove. This means that engraved MDF can last for a very long time and thus is ideal for designs with a long service life in mind.

The maximum thickness of MDF that can be laser cut depends on a lot of factors which mostly depend on the laser cutter. An ideal laser beam would never diverge nor would lose power over distance, but the real world is far from ideal. Real beams from laser cutters diverge over distance (called laser kerf), and as the beam diverges the laser is less able to cut material while the cutting area is increased. In the case of MDF, Ponoko offers a wide range of MDF materials whose maximum thickness is 0.25 inches. Ponoko also offers a wide range of MDF types and designs including MDF fiberboard, Melamine MDF, standard MDF, and premium veneer MDF.

MDF can be used in applications that require structural strength, machinability, non-conductive surfaces, and aesthetic properties. One area that sees MDF most is furniture thanks to MDFs structural abilities while also being very cheap. MDF can also be used in enclosures for electronic products and is commonly used in speakers that require cavities to improve the performance of speakers. MDF can also be used for intricate parts thanks to the ability of laser cutters to produce features as small as 1mm x 1mm. Furthermore, the strong engraving contrast combined with the precision provided by laser cutters allows for complex parts to be mass-produced with ease.

When cutting materials with laser cutters it is essential that the space between the target and the laser head is completely free from any obstruction. Since laser cutting MDF produces large amounts of smoke, active ventilation is required to prevent the smoke from interfering with the laser beam. The produced smoke can also discolor the surrounding area of MDF and can require painting or cleaning. Often MDF sheets use formaldehyde as a glue agent and therefore can produce toxic gases during the cutting process. However, Ponoko strictly uses high-grade engineered MDF that is not high in formaldehyde, and is Compliant with the California Air Resources Board Phase 1 Formaldehyde Emission Standards for Hardwood Plywood (HWPW), Particleboard (PB), and Medium Density Fiberboard (MDF).

Ignoring the many benefits of MDF and the advantages that cutting with a laser has, there is one major reason why Ponoko should be your first choice; scalability. Ponoko offers customers the ability to purchase quantities as high as ten thousand and as few as one. This means that engineering projects can rapidly prototype a design and then scale it to full-scale production using the same cutting service.