Our Milling Process
A profile is the milled (cut) visible surface of the finished material, which becomes part of the decor in your home. We have hundreds of existing profiles in our profile library. We can design a new profile by scanning a sample of material, an outline or sketch, and creating a dimensional drawing in AutoCAD.
Using the AutoCAD drawing, we create a program for our CNC router to carve the profile into a piece of cast acrylic (plastic), creating a template. For replications, the original moulding is tested against the template to ensure a match.
Using the template, a steel plate is machined to create the profile knife. The knife is inserted into a head that is placed into a machine called a moulder, ready for production.
The Finished Product
Raw lumber is ripped (cut lengthwise) to dimensions slightly larger than the finished moulding to minimize waste during production. Rip off cuts are used to make smaller mouldings. The ripped lumber is fed through the moulder where the knife head rotates at high speeds carving the profile into the wood.