When working with high-quality polymer sheets from King Plastic, using the right tools and techniques ensures precise, professional results. If you’re a cabinet maker, outdoor furniture craftsman, making OEM boat parts, sign maker, or DIYer, you know that high-quality materials make all the difference in durability, performance, and aesthetics. King Plastic’s polymer sheets can withstand harsh outdoor environments making them an ideal building material for a variety of projects—whether you’re working on fabricating cabinets, outdoor furniture, boat components, or outdoor signs.
To achieve the best results when routing and engraving King Plastic polymer sheets, we’ve put together expert tips, recommended tools, and techniques for working with King Plastic polymer sheets.
Which King Plastic Material Is Right For Your Project?
Choosing the right King Plastic material for your project depends on the application, environment, and desired durability. King Plastic offers a range of high-density polyethylene (HDPE) sheets, each designed for specific uses. Here’s a quick guide to help you select the best material for your project:
King StarBoard®
Marine Applications
Best for: Boat parts, marine furniture, and environments exposed to harsh outdoor conditions.
- Key Features:
- UV stabilized and highly resistant to moisture, saltwater, and marine environments.
- Doesn’t warp, swell, or delaminate, making it the perfect wood replacement for marine use.
- Common Uses:
- Fabricating boat components, such as hatches, doors, and trim.
- Building outdoor furniture for coastal and marine settings.
King StarBoard® ST
Cabinetry & Furniture
Best for: Cabinets, outdoor furniture, and projects requiring high rigidity.
- Key Features:
- 25% stiffer than the original King StarBoard®, offering greater rigidity.
- UV stabilized and resistant to moisture, making it perfect for outdoor or high-humidity environments.
- Common Uses:
- Building cabinetry for kitchens, bathrooms, and RVs.
- Outdoor furniture that can withstand extreme weather conditions.
King ColorCore®
Signage
Best for: Engraved signs, displays, and projects requiring vibrant color contrasts.
- Key Features:
- Multi-layer HDPE with contrasting colors for easy engraving.
- High impact resistance and weather durability for indoor and outdoor use.
- Common Uses:
- Fabricating durable outdoor signs for parks, playgrounds, and commercial properties.
- Custom engraved panels for branding and product displays.
Once you’ve selected the right King Plastic material for your project, the next step is using the proper tools to ensure precise fabrication. One of the key advantages of King Plastic’s HDPE polymer sheets is that they can be fabricated using standard woodworking tools, making it easier for cabinet makers, outdoor furniture builders, boat parts fabricators, and sign makers to craft professional-quality products.
Cutting Tools
- Table Saw – Use a table saw with a sharp carbide-tipped blade for straight, clean cuts.
- Blade Type: Triple-chip grind or alternate top bevel (ATB) blades are ideal for cutting HDPE sheets.
- Tip: Feed the sheet at a steady pace to avoid melting or rough edges.
- Circular Saw – A circular saw works well for cutting large polymer sheets down to size.
- Blade Diameter: Use a 7 1/4” or larger blade for smoother cuts on thick sheets.
- Tip: Keep the saw moving to prevent heat buildup and melting.
- Jigsaw – Perfect for cutting curves or intricate designs.
- Blade Type: Use a fine-tooth blade or one designed for plastic cutting.
- Tip: Set the speed to medium or high and avoid forcing the blade through the material.
Drilling Tools
- Hand Drill or Drill Press – Either tool works well for drilling holes in King Plastic polymer sheets.
- Drill Bits: Use standard high-speed steel (HSS) bits or brad point bits for clean holes.
- Tip: Drill at a moderate speed and periodically pull the bit out to clear chips and prevent overheating.
- Countersink Tool – Ideal for projects requiring flush screws, such as cabinetry or furniture.
- Tip: Use a countersink bit designed for plastics to avoid cracking the surface around the hole.
Routing Tools
- Best Bit Type: For most applications, an up-cut O-flute bit is recommended. It efficiently removes chips and minimizes heat buildup during the cutting process.
- Recommended Bit: The Onsrud 63-781 3/8” up-cut O-flute bit. It has a 3/4” cutting edge length (CEL) and works well on polymer sheets up to 3/4” thick.
- Bits to Avoid:
- Down-cut bits may be used if there’s sufficient room for chip removal, but they’re less efficient than up-cut bits.
- Bit Diameter & RPM:
- For bits between 1/4” and 1/2” diameter, keep the RPMs between 18,000 and 20,000.
- Feed Rate:
- A feed rate of 150-250 IPM works well, but this depends on the rigidity of your CNC machine and the depth of each cut.
- As a rule of thumb, cut no deeper than the diameter of the tool.
- Adjusting IPM:
- If your RPM differs significantly from the 18,000-20,000 range, adjust your IPM proportionally to maintain optimal chip load and cutting quality.
- How to Reduce Swirl Marks
- Use a Rounded-Bottom Bit to help reduce swirl marks.
- Use a Rounded-Bottom Bit to help reduce swirl marks.
Key Takeaways
- Use an up-cut O-flute bit for most applications to ensure smooth cuts and proper chip removal.
- Maintain 18,000-20,000 RPM and a feed rate of 150-250 IPM for bits 1/4” to 1/2” in diameter.
- Cut no deeper than the diameter of the tool for the best finish.
- To reduce swirl marks, use a rounded-bottom bit and lower RPMs for wide profile bits when needed.
With the right tools and tips, you’ll be able to fabricate King Plastic polymer sheets with precision and ease.
Additional Resources
For more detailed information on CNC settings, tool selection, and fabrication techniques, check out these helpful resources:
🔗 CNC Fabrication Page
🔗 CNC Quick Fact Sheet
🔗 General CNC Information
🔗 Engraving King ColorCore Guide
🔗 Works Like Wood Guide
🔗 Videos
