6 minute read -
Cutting Chipboard: Which Saw to Use and How to Prevent Chipping
Chipboard is cut most neatly with a circular saw or table saw fitted with a carbide-tipped blade with a high tooth count, run along a guide rail or straight edge. For curves and cut-outs, use a jigsaw with a fine blade.
You prevent chipping when cutting chipboard by placing the good face on the correct side, taping or scoring the cutting line and not forcing the saw.
What will you learn in this article?
- Why does chipboard chip when you cut it?
- Which saw should you use for chipboard?
- Which blade should you use for chipboard?
- How to prevent chipping in chipboard
- How to cut chipboard straight, step by step
- How do you finish chipboard edges?
- Which chipboard should you choose?
- Cutting chipboard safely
- Frequently asked questions about cutting chipboard
- In short: cutting chipboard
Why does chipboard chip when you cut it?
Chipboard is made of wood chips bonded with glue and pressed into a board under high pressure. That gives it a grainy core, and the glue blunts saw blades more quickly. Melamine-faced chipboard has a hard plastic surface on both sides. That surface breaks out easily where the saw teeth leave the material, which is where you get the familiar white flakes along the cut.
Which saw should you use for chipboard?
| Saw | Suitable for | Good face |
|---|---|---|
| Circular saw with guide rail or straight edge | Long, straight cuts in large boards | Facing down |
| Table saw | Straight cuts in small and medium boards | Facing up |
| Jigsaw | Curves, cut-outs, short cuts | Depends on the blade, see below |
| Handsaw | A single short cut | Facing up |
Cutting chipboard with a circular saw
A circular saw is the best choice for most jobs. The blade rotates forwards at the bottom and exits the material at the top, and that is where chipping happens. So place the good face down. Use a carbide-tipped blade with a high tooth count for fine cuts in sheet material. Set the cutting depth so the blade comes out a few millimetres below the board. A cordless circular saw from the Batavia Maxxpack 18V range is handy for boards you cut to size on site or in the shed. Check the saw's specifications for the right blade size and its maximum cutting depth.
Cutting chipboard on a table saw
On a table saw the blade runs down through the board from the top. Chipping happens on the underside, so place the good face up. Do not let the blade protrude too far and use a push stick for narrow strips.
Cutting chipboard with a jigsaw
A standard jigsaw blade cuts on the upstroke and pulls the top surface loose. For melamine-faced board there are reverse-tooth blades that cut on the downstroke, which keeps the top face cleaner. Switch the pendulum action off or set it to the lowest setting and choose a medium speed. A jigsaw is less suited to long straight cuts, as the blade tends to wander.
Which blade should you use for chipboard?
- Choose carbide-tipped teeth (TCT). Plain steel goes blunt quickly in chipboard because of the glue.
- Choose a blade with a high tooth count for sheet material and laminate. Fewer teeth cut faster, but rougher.
- A triple-chip or alternate top bevel tooth gives a crisp edge in melamine-faced chipboard.
- Replace the blade or have it sharpened as soon as you see more chipping or the saw needs more pushing.
How to prevent chipping in chipboard
- Cover the cutting line with strong masking tape and cut through the tape. The tape holds the surface layer together.
- Score the surface along the cutting line first with a sharp knife and a steel rule.
- Make a shallow first pass of about 1 mm, then cut right through on a second pass. Some guide rails have an anti-splinter strip that does the same job.
- Use a rail or guide so the saw cannot wobble.
- Push steadily and evenly. Too much pressure causes more breakout.
How to cut chipboard straight, step by step
Measure and mark
Measure the size you need and draw the cutting line with a pencil and a straight edge or square.
Support the board
Lay the board on two trestles or a workbench and support both parts, so the offcut does not break off at the end of the cut.
Clamp a guide
Clamp a guide rail or straight edge in place, set at the distance between the blade and the edge of the saw's base plate.
Tape or score the line
Put tape over the cutting line or score the surface layer with a knife.
Make the cut
Switch on the saw, let it reach full speed and cut through in one smooth movement.
Finish the edge
Clean up the edge with fine abrasive paper or a file and check the measurement.
How do you finish chipboard edges?
Lightly sand rough edges with 120 to 180 grit on a sanding block, angled away from the surface layer to avoid breakout. On melamine-faced chipboard, iron on or glue edging tape to the cut edge afterwards. You can also trim a crisp edge with a router and a trimming bit, although that is an extra step. Untreated edges absorb moisture and swell, so always seal them in kitchens and bathrooms.
Which chipboard should you choose?
- Melamine-faced chipboard: has a plastic surface on both sides. Handy for cabinets and furniture, because it does not need painting.
- Moisture-resistant chipboard: for rooms with higher humidity, such as a kitchen or bathroom. It copes better with moisture, but it is not waterproof.
- Fire-retardant chipboard: for applications with fire safety requirements.
All of these boards are cut the same way. Moisture-resistant and fire-retardant chipboard are often a little harder, so the blade wears slightly faster.
Cutting chipboard safely
Chipboard dust is fine and contains glue residues. Use dust extraction, wear an FFP2 dust mask and safety glasses, and use ear defenders. Make sure the board is well supported so the blade does not bind. Remove the battery or unplug the saw before you change the blade or adjust the cutting depth.
Frequently asked questions about cutting chipboard
Which side do you cut chipboard from with a circular saw?
With a circular saw, place the good face down, because chipping happens on the top. On a table saw it is the other way round and the good face goes up.
Can I cut chipboard with a jigsaw?
Yes, especially for cut-outs and curves. Use a fine blade or a reverse-tooth blade and switch off the pendulum action. For long straight cuts, a circular saw is better.
How do you cut melamine chipboard without chipping?
Tape the cutting line or score the surface with a knife, use a carbide-tipped blade with a high tooth count and cut with a guide. A shallow first cut followed by a full-depth cut gives the neatest edge.
Is chipboard dust harmful?
Fine wood dust is harmful to your lungs, and chipboard also contains glue residues. Work with extraction and an FFP2 dust mask, and vacuum the work area thoroughly afterwards.
In short: cutting chipboard
Use a circular saw or table saw with a carbide-tipped, high tooth count blade for straight cuts, and a jigsaw with a fine or reverse-tooth blade for curves. Place the good face down with a circular saw and up on a table saw. Tape or score the line, cut without forcing and finish the edges with edging tape.
