New inlay feature works great

I finally got around to testing the new inlay update discussed in this thread:

Long story short - It worked absolutely great the first time.

I shamelessly used the same familiar barista for my test, inlaying end-grain walnut into end-grain hickory:

I used a new 30° Vee Bit (with a .005" tip) and the “Plug Depth” and “Top Gap” recommendations from @wmoy.

My pocket depth was .25". The recommendation is to make the plug depth .5mm (.02") less than the pocket depth, so my plug depth is .25" - .02" = .23".

For the Top Gap, the recommendation is to use 1mm (.04")

The pocket in Hickory:

The plug in Walnut:

Before gluing, the top gap is ~1.5mm:

After gluing under significant clamping pressure, the final top gap is ~1mm:

Then I cut the poor girl in half to get a cross section:

The “glue gap” is ~.008".

I think the keys to success are:

  1. Use the recommended settings for Plug Depth and Top Gap
  2. Use perfectly flat stock
  3. Use a Vee bit with a sharp (not broken) tip
  4. Use a BitZero and BitSetter to “nail” your Z and eliminate job setup errors
  5. Clean up the fuzzies so they don’t interfere
  6. Clamp the heck out of it
  7. Don’t forget to mirror your plug!

Now on to some inlayed endgrain cutting boards…

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That’s a great writeup, Steve; thanks for the pics.

My favorite part of the Starbuck test is to see how even the tiny nose element comes out. On our test, it was very small and it was perfect.

Looking forward to the cutting boards photos.

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I have used hickory a couple of times. That stuff is hard. The only thing I have cut that is harder is Osage Orange. I got a free piece of Osage Orange from a door prize at our woodworking club. The group called it Bodark. I came home and looked up Bodark and found nothing. Well I guess Bodark is Texas pronunciation of Bois De Arc. The french name for Osage Orange. Native Americans use green Bodark to make bows. Once it dries much like hickory it is hard and springy. Bodark grows naturally in the southern US.

Glad your inlay came out so good. I was failing to get good inlays and posted here on the forum and @wmoy chimed in and things worked out well. Before the CC inlay I used the Vetric method and that came out good but started the inlay at .1" below the top and that was rather hard on the cutter. My last inlay came out very good.

I used the keyhole toolpath to do the hangers on the back. CC just keeps getting better and better. I started with CC 3 but have not yet used the CC 8.

The plaque is 11 x 14" and is made of Mesquite and Maple. Dr Kulhavy is a professor at SFA in the forestry department so I thought the wood used were approporiate.

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Indeed it is. And heavy too. These were just small scraps that I had laying around for this test - they came from near the center of the tree and the wood looks “dirty” to me - not suitable for a real project.

Yes it does - I was once tempted by Vectric, but not anymore. And kudos to Carbide3d for making their software compatible with both Windows and Mac (something Vectric doesn’t do). This was a key buying decision for me.

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Here’s another test. Same Top Gap as before (1mm; .04"), but this time with a plug depth .03" less than the pocket depth. So in this case the plug depth is .25" - .03" = .22". Inlay came out perfect again. Here’s some cross sections:

The resulting bottom/glue gap is ~.022". Because I’m dialing this in for a cutting board, I think this bottom gap is too big. I think these gaps would result in a hollow sound in the finished product when tapping on a bigger inlay. I want it to sound and feel solid.

I’ll stick with my original settings: Top Gap = 1mm (.04") and Plug Depth .5mm (.02") less than the pocket depth. [Exactly what @wmoy has previously suggested :wink:].

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If I download CC777, for the inlay update, will it overwrite my Pro version?

Installing a newer version of Carbide Create will overwrite the current version if the same major version, and will use the installed Pro license if it is within one year.

If you install a new major version it will not overwrite a previous version, but will use the Pro license if valid (if not the license will need to be updated or disabled).

Understood, Thank you. Would I be able to keep my pro version, as is, (the year has gone by) and install the free (newer) version to another directory, Therefore using the features of my pro version when I want, and then switching to the free version when I want to do an inlay?

Not quite.

You will either need to update your Pro license, or selectively enable and disable the Pro license — any version of Carbide Create will see a Pro license if present.


Im hoping I didnt go too small/fine. Now glued and clamps are on. Tomorrow feels like Dday…

3 more boards with even finer details (wheat stalks). Let’s see if they come out well! Will keep you posted.

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It seems to me that there should be a way to calculate the minimum workable width given the bit used and depth. And maybe whether face or end grain. I did some tests earlier and had to make multiple adjustments to the thinner pieces until Ingot something that worked.

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Your parts look good in the pic. If you have trouble with finer detail (wheat stalks), try using end grain for the plug. It’s a pain to glue up the blanks (like a mini end grain cutting board), but end grain holds amazing fine detail without chipping, in situations where face grain won’t.

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