Wednesday, July 21, 2010

Experimenting with Corian on the scroll saw.

I don't cut a lot of Corian. It's a fun product to work with because it's so different from wood. I decided I should spend a little time learning the ins and outs of cutting the product and making it look nice.

The first thing to know is that Corian can be expensive. It runs about $20/sf. The good news is that most scroll saw projects are small so you don't need a lot of the material. It's best to try and find your local counter top installer and buy or trade for their scraps. You can also find scraps of Corian sold on It's also heavy so shipping charges are high.

Using the correct blade is important. A skip tooth blade like the Flying Dutchman Polar blade will cut Corian well. I also used the "True Cut Blades Hook Tooth GT" with good results.

Feed rate and blade speed are also important. If you feed too fast you will cause friction heat and melt the Corian as you cut. This heat will fuse the material back together. You will know this has happened when you try to remove the piece from the waste area. It won't come out. Even using the correct feed rate you can get some fusing. In the test piece above I used packing tape over the pattern of the man but not on the base. I had no fusing with the tape but without it fusing occurred. This caused a lot of sanding to get the base edges smooth after I had to break it out of the waste. Always use the tape.

Sanding and polishing are a work in progress for me. You can see on the test piece above that there is a difference in the gloss from the pre-finished front and the edges I cut and sanded. It's not severe but noticeable up close. After researching online I have found that there are products to remove scratches and polish the Corian to a high gloss finish. Some online sources suggest a buffing wheel to get a really nice high gloss. I'm working on that.

Cyanoacrylate(Super Glue) is the glue for assembling Corian pieces together. In the test cut there is very little glue area between the base and the foot but the CA glue made the joint strong.

I love cutting wood. I like the natural beauty of the grain. I like the way it feels. I like the way it smells. I like the way it cuts. I just like wood but Corian gives us another material to add to our arsenal. Small art pieces, key fobs, name plates and desk sets are just a few of the projects that come to mind using Corian. If you get a chance, give it a try.

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Free Pattern Catalog. 1000's of free patterns.

Thousands of FREE scroll saw patterns. No registration or signup required.

The projects form these patterns can be sold without restrictions. The patterns cannot be sold.

Click here for the Free Online Catalog.


Wooden Vases on the Scroll Saw Book $12 Each
Each digital book is available for download immediately after payment.
The books are $12 per edition and contains eight unique patterns each.
Watch the following video to see how easy these beautiful scroll saw vases
are to make. 

Order the $3 pdf Catalog

This is a PDF of all the patterns in my free catalog. It is for Windows only and has a program to automatically download the pattern to your computer. Please watch the video below before you order. Click the picture to order.
You do not need a PayPal account to order. At the bottom of the PayPal page is a button that will allow you to pay with a credit card. After successful payment click the Return to Merchant button for the download.

Stencil Printer 1.7

Stencil Printer Instruction Video.

The Scrollsaw Workshop Stencil Printer 1.7 is my latest software for creating patterns. It will create key chain fobs, desk name plates and more. Click the image above to download the latest version. It is free to use donationware. This software is for Windows PC only.

Scroll Saw Pattern Printer update 1.1

Scroll Saw Pattern Printer update 1.1
Download the Free Scroll Saw Pattern Printer Version 1.1. Create name patterns in seconds. Windows PC only.
Download Version 1.1
Please consider a $5 donation for The Scroll Saw Pattern Printer v1.1.

Scroll Saw Keychain Pattern Maker

Use the Scroll Saw Keychain Maker to start a small keychain business. Build yourself a nice display and make up severl keychains with common names. Sell at craft shows, on Ebay or at work. Everyone needs a keychain. Take custom orders. Heck just make them and give them away as gifts. It's all made easy with the Scroll Saw Keychain Maker. Watch the video demonstration then download the file below and get started with the fun.
The following link will start the download process. After the file download is complete just click the setup file and the program will be installed. Please consider a $5 donation for the program.

Download the Oval Keychain Pattern Maker.

Enjoy designing and printing these great personalized key chains. Give them as gifts, make them for fun or sell them at craft shows. It's easy, just watch the video demo then download and install the program. You will be designing these fun projects in minutes. Windows PC only.
Download the Free Oval Key Chain Pattern Maker. Create Oval key chain patterns in seconds.
Download Version .9a
Please consider a $5 donation for The Oval Key Chain Pattern Maker.

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T-Shirts and More.
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The Lifter

Papa's Custom Patterns.

Philip Lowndes Noah's Arc Pattern Available. Watch the video below.

This video is from Philip Lowndes. He is the designer of this beautiful Noah's Arc puzzle pattern. If you would like the pattern follow the link below.
Buy This Wonderful Heirloom Puzzle Pattern

Think Safety

Remember to keep the safety of yourself and others in your work shop in your thoughts at all times. Always wear eye and ear protection. Follow all the manufactures warnings that came with your power tools. If I demonstrate something on this web site that you don't feel is safe, don't do it. Your safety is your responsibility. Fingers are handy things, try to keep all of them.
The Scrollsaw Workshop Blog is in no way affiliated with or sponsored by Scroll Saw Woodworking and Crafts Magazine formerly (Scroll Saw Workshop Magazine) or it's publisher Fox Chapel Publishing.

Scroll Saw Woodworking and Crafts