Face Milling
Definition and Explanation of Face Milling in Woodworking
Face milling is a technique that allows you to mill a piece of wood to the desired thickness. Precise angles and uniform surfaces are essential for beautiful, high-quality wood products. Raw lumber from the sawmill is not immediately suitable for decorative purposes; it must first be dried and processed. Face milling helps you create a smooth and even surface.
In this article, you'll learn how face milling differs from other techniques, what materials you can machine with it, and what other possibilities a milling machine offers.
Flat Milling a Wooden Plank with a Router
Table of Contents
- Definition
- Technical Fundamentals of Face Milling
- What types of face mills are used for face milling?
- What materials are used in face milling?
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Applications of Face Milling
- Creating a Flat Surface
- Facing of Irregularities and Protrusions
- Pockets, recesses, and cutouts in surfaces
- Face-mill protruding edges
- Facing tree stumps or end-grain cutting boards
Definition: What is face milling?
When surface planing, you remove material from the uneven surface of a solid workpiece so that it becomes as smooth and flat as possible. It is a secondary process that follows immediately after cutting. Professional woodworkers typically use planers (jointer and thicknesser) to “plane” pieces of wood quickly and efficiently. However, their width is limited, and they can only process rectangular cross-sections. A surface planer is slower, but more versatile—it can process solid wood pieces or wood-based materials of virtually any size, which is particularly useful for tree stumps or epoxy-filled wood panels.
Technical Fundamentals of Face Milling
A typical face milling machine consists of the following components:
- Router
- appropriate replacement tool (face mill)
- Workbench with clamping devices
- Milling device with XY guide and plunge mechanism
Everything is available on the market, from simple hobby solutions (a collapsible router table with a hand-held router) to professional CNC-controlled machines. The router itself allows you to mount various cutters, such as indexable-insert cutters. Thanks to the XY guide, you can move the machine along two axes and lock it in place at the desired positions.
Machine
A hand-held router with a compatible guide system is the foundation. Make sure the shank sizes are compatible (8, 10, 12 mm) and that the speed is adjustable—speeds that are too high can cause scorch marks in soft wood or quickly dull the bit.
Tool
In the router, use cutters with the widest possible cutting width for face milling (typically 30 mm in diameter). Indexable-insert cutters are advantageous because you can rotate or replace the insert as it wears down. Finger cutters with fixed cutting edges are also an option, but you should opt for low-wear carbide versions.
Milling pockets, recesses, and notches in a surface
Milling Device
It consists of rails (XY guide) along which a carriage with a plunge mechanism for the router runs. This allows you to move the machine in a controlled manner along both axes or lock one axis—for example, to “trim” a workpiece. Higher-end systems are precision-engineered, can be disassembled, and can be stored in a space-saving manner.
SlabMatrix milling unit on the RUWI-lifting table
Work surface
A sturdy, level workbench provides a stable base so your workpiece rests securely. A sufficiently large perforated panel with the appropriate clamping system is a good choice. Professional workbenches are often height-adjustable and come equipped with plenty of accessories (clamps, stops, etc.).
Flat milling on a large joiner's table with trestles
Tip: The RUWI-router table (a portable table router) combines the advantages of a sturdy worktable with the flexibility of a router.
What types of face mills are used for face milling?
In most cases, face mills with an 8-mmshank and a diameter of about 30 mm are sufficient. Two or three cutting edges are standard. Popular brands include Titmann and ENT. It is important that the face mill is sturdy enough to withstand the high stress involved in face milling.
What materials are used in face milling?
Face milling is primarily used to level uneven surfaces, especially in solid wood. Wood-based materials such as particleboard, glued laminated timber, or plywood are usually already relatively smooth, so sanding is often sufficient. Nevertheless, you can also use face milling cutters to machine material composites (wood and acrylic or epoxy resin). Just make sure there are no metallic inclusions that could damage your router bit.
Flat-milling a tree pit made of solid wood
Applications of Face Milling
You can use a face mill in many different situations:
- Creating a flat surface: Processing solid wood boards, beams, and blocks into semi-finished products.
- Facing of uneven surfaces and protrusions: For example, planing uneven joints smooth after gluing.
- Pockets, recesses, and cutouts: Mill rows of holes or openings for glass panels or lamps into the surface.
- Facing protruding edges: Precisely sizing workpieces or adding profiles.
- Facing tree stumps or end-grain cutting boards: End grain is difficult to plane, but can be smoothed easily with a router.
You might also be interested in these milling processes:
If you'd like to learn about other milling techniques used in woodworking, check out our glossary for information on CNC milling, profile milling, groove milling, and more.
