How To Make an American Flag in Wood using Amana Tool® CNC Router Bits, Saw Blades and Vectric VCarve Pro

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For Your Safety

  1. The methods illustrated here are only intended for use with a CNC machine and Saw machines.
  2. Make certain that the workpiece is secured and that all components of the fixture are securely fastened to the table.
  3. Use a guard, eye and hearing protection at all times.

Watch step-by-step as we design, cut and carve this American Flag using Amana Tool® CNC Router Bits and Saw Blades. We chose White Maple, Dark Walnut and Paduk for their natural colors to best represent the red, white and blue of the American Flag, without using a dye or paint to color the wood. Final dimension measure 46" wide x 26" tall x 7/8“ thick.

Andy Glass from Workshop Addict takes the following steps to create the America Flag:

Step 1
At the computer using Vectric’s VCarve Pro, Andy modifies the American Flag .STL file to fit our dimensions and customizations for CNC use

Step 2
Using the AGE® Series Track Saw Machine Saw Blade no. MD260-800 in his Festool® KS12 EB miter saw, Andy trims the wood to size.

Step 3
At the table saw, Andy uses AGE Series Glue Line Ripping Saw Blade no. MD10-301 to rip all the boards into the strips needed for the stripes.

Step 4
Biscuit joiner and glue up to increase the stability of the thick flag. Five different glue ups were needed.

Step 5
Amana Tool Extra-Fine Cutting, Electro-Blu™ Coated Saw Blade no. 610801C to crosscut the panels on a table saw with the sled dialed in at 90°

Step 6
In preparation for CNC cutting on his Rockler CNC Shark HD 3 w/ Extended Bed CNC Machine, Andy uses Amana Tool Heavy Duty Insert Knife Spoilboard Router Bit no. RC-2255 to flatten and old, worn out piece of MDF Spoilboard from his CNC bed.

Step 7
To prepare the stars for placement, Andy uses Amana Tool’s Insert Knife V-Groove Router Bit no. RC-1108 to inlay the wood.

Step 8
Amana Tool Spiral Flute Plunge Router Bit no. 46245 roughs away most of the material around the starts for the next inlay

Step 9
Switching back the the 60° RC-1108 Router Bit, Andy cuts the stars from the white maple in preparation for gluing them into the flag

Step 10
Amana Tool Spiral Flute Plunge Router Bit no. 46248 cuts the slot that will be used along with no. 45650 to make the keyhole slot to hang the American Flag

Step 11
After gluing in the stars, Andy again uses the Spoilboard Router Bit no. RC-2255 to remove access material. He then sands away the excess material, however he could have inched his machine further down to get a closer finish with this unique Spoilboard Router Bit.

CNC Feed, Speed & Step Down Technical Information:

Heavy Duty CNC Insert Carbide Spoilboard 3 Wing Amana Tool CNC Router Bit No. RC-2255
Feed Rate (IPM): 300"
Speed (RPM): 18,000
Chip Load (Per Tooth): 0.006"
Step Down (Per Pass): 0.125”

60° Insert V-Groove Amana Tool CNC Router Bit No. RC-1108
Feed Rate (IPM): 40"
Speed (RPM): 18,000
Chip Load (Per Tooth): 0.003"
Step Down (Per Pass): 0.125”

Solid Carbide Spiral Flute Plunge 3/16” Diameter Router Bit No. 46245
Feed Rate (IPM): 110"
Speed (RPM): 18,000
Chip Load (Per Tooth): 0.003"
Step Down (Per Pass): 0.250”

Solid Carbide Spiral Flute Plunge 1/4” Diameter Router Bit No. 46248
Feed Rate (IPM): 110"
Speed (RPM): 18,000
Chip Load (Per Tooth): 0.003"
Step Down (Per Pass): 0.250”

Carbide Tipped Keyhole Router Bit No. 45650
Feed Rate (IPM): 110"
Speed (RPM): 18,000
Chip Load (Per Tooth): 0.003"
Step Down (Per Pass): 0.250”

CNC Video: How To Make our American Flag in Wood using Amana Tool CNC Router Bits, Saw Blades and Vectric’s Carve Pro

Purchase and download this Vectric VCarve Pro file ready to cut Here.

If you would like to learn more about Workshop Addict, please visit their website or YouTube channel

http://www.youtube.com/workshopaddict
http://www.workshopaddict.com

Other Links
Amana Tool: http://www.amanatool.com
Vectric VCarve Pro: http://www.vectric.com/products/vcarve.htm

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