Dave Hebson - Chess Board

Project Overview

This chessboard was crafted using a medium-sized oak worktop offcut, featuring walnut and maple inlays for the alternating squares. The precision of the VCarve inlay technique, calculated in Vectric Aspire, ensured a seamless and professional finish.

Design & Workflow

The VCarve inlay toolpaths were initially generated in Aspire, after which the square layout was adjusted to fit the available stock. Recalculation was performed to optimize placement and ensure an accurate fit.

Due to variations in stock thickness between the two wood types, the inlay glue-up was completed in two stages. Once assembled, all surfaces were sanded, sealed, and finished with wipe-on polyurethane for a smooth and durable surface.

Key Considerations

• A boundary offset was applied to both the 3D roughing and finishing toolpaths to control the depth of the board shape cut. This left an approximate 3mm depth for the final profile cut with tabs.
• If modifying the finishing tool size, the boundary offset must be adjusted accordingly (e.g., an 8mm ball nose requires a 3mm offset, whereas a 6mm ball nose would need a 2.8mm offset).

Cutting Tools Used

• 3.175mm Endmill - VCarve inlay socket & plug clearance
• 60° V-Bit - VCarve inlay socket & plug cutting
• 6mm Endmill - 3D clearance & profile cutting
• 8mm Ball Nose - 3D finishing
• 32mm Surfacing Bit - Flattening stock & inlaid squares

Additional Tools

• Bandsaw - Separating inlaid squares
• Clamps - Securing glue-up

Aspire Features Utilized

• 3D Modeling – Created the angular shape for the board.
• V-Inlay Toolpath – Ensured precise inlay fitting.
• Tool Keep-Out Zones – Defined areas to control tool movement and cutting boundaries.

Material Requirements

• Oak Worktop - 400 x 400 x 30mm - Flattened on CNC before starting
• Hardwood Boards (Light & Dark) - 650 x 84 x 15mm (x2) -Pre-flattened before machining

This project showcases the power of Aspire’s VCarve inlay feature and highlights the precision of CNC machining in fine woodworking. The result is a high-quality, handcrafted chess set, combining elegant material choices with expert toolpath execution.