Dragonfly end grain cutting board handmade in Sydney with intricate maple and myrtle inlay

Behind the Inlay: Making a Hugin Design End Grain Cutting Board

There's more to an intricate end grain cutting board than its finished appearance suggests. The details aren't printed onto the timber: they are carefully machined pieces of contrasting wood, fitted into an end grain base and finished by hand.

In a recent Trend Timbers customer feature, Fred shared some of the practical challenges behind the CNC inlays we make at Hugin Design in Sydney. Here is a closer look at that process.

Choosing timber that machines cleanly

For intricate end grain inlays, clean machining is critical. Our goal is to minimise splintering and tear-out, particularly around fine shapes. Straight-grained, fine-textured hardwoods generally respond well to careful CNC machining.

American black walnut is our preferred base timber because we like its rich colour and machining characteristics. Canadian rock maple provides strong contrast against the walnut and is well suited to the delicate details. Selected designs also use Tasmanian myrtle.

Every species behaves a little differently, so timber selection is about more than colour. The quality and preparation of the material influence the fit and finish of the inlay.

Preparing the end grain base

Even before the CNC cuts begin, an end grain base has to be made accurately. Each of our bases requires two separate glue-ups. We allow each to cure overnight, so the base preparation alone typically occupies two days.

The contrasting inlay timber also has to be made from end grain, and we usually prepare those pieces alongside the base. This keeps the process organised while allowing the glue to cure properly.

From design to precise CNC toolpaths

A complex inlay starts long before the machine runs. Toolpaths must account for the shape of the design, the properties of the wood and the cutter being used.

Creating a precise fit between the matching parts requires attention to the cutter's radius, material flatness, machine setup and machining strategy. G-code, suitable end mills, speeds and feed rates all play a part. For particularly fine details, small errors in the setup can become very obvious in the finished piece.

Depending on the complexity, the actual machining can take around 3–12 hours.

Dragonfly end grain cutting board in American walnut with Canadian maple and Tasmanian myrtle inlay
The Dragonfly is among our more intricate designs, with five layers of inlay work.

Why the glue-ups take patience

Careful glue-up is just as important as accurate machining. Each additional inlay glue-up adds roughly another day to the overall process because the work needs to be assembled accurately and the adhesive allowed to cure.

Good results depend on a combination of timber quality, precise glue-ups, correct machine setup and an organised workflow. It's not just about having a capable CNC router.

Shaping, sanding and finishing

After the inlay work, we flatten and shape the board, sand the surfaces and apply a food-safe finish of mineral oil and beeswax. These finishing stages can take another few days, depending on the board.

The KOI board, for example, includes both rock maple and Tasmanian myrtle inlays and typically takes approximately 6–7 days from start to finish. More intricate boards can take longer.

Finished KOI cutting board with walnut base, rock maple and Tasmanian myrtle inlay
The KOI combines rock maple and Tasmanian myrtle inlays in a black walnut end grain board.

Years of learning behind the finished board

Learning the process was not an overnight achievement. Fred spent several years developing general CNC skills before attempting complex end grain inlay work. That included learning design software, G-code generation, machine operation, tool selection and machining parameters.

With that foundation in place, it took a further few months to refine the inlay settings and workflow. We still adjust and learn from each new board we make.

For anyone starting out with CNC inlays, our advice is to begin with simple geometric designs, understand your toolpaths, keep the workpiece flat and use suitable tools. Test cuts are essential, as is understanding how the matching male and female parts fit together. Above all, don't rush: a small mistake can ruin a piece that has already taken days to prepare.

Woodworking and technology, together

CNC technology makes these precise designs possible, but every successful board depends on the decisions around it: choosing and preparing timber, organising glue-ups, getting the fit right and finishing by hand.

Hattori Hanzo walnut and maple end grain cutting board handmade by Hugin Design
The Hattori Hanzo board is another example of detailed end grain inlay woodworking.

Explore our handmade end grain cutting boards, including the Dragonfly, KOI and Hattori Hanzo. You can also read the original Trend Timbers feature.

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