maze board

Project By: Thechuck21

Maze Board cut from .75 inch MDF with a .93 inch sheet of Plexiglas with Airsoft BB's for marbles


Type Length Width Thickness Origin
Name Type Tool Feedrate Plungerate Cut Depth

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I secured the MDF to the spoil board using masking tape and super glue. I then cut out the hand hold, outside profile, and pocket for the Plexiglas using a .25 inch endmill 201 from Carbide 3D.

I then switched to a .125 straight flute endmill from home depot to cut out the maze path. Next I switched to a 1/8 inch roundover router bit that had a .5 inch bearing on it that I removed and ground off the piece that holds the bearing in place. with the roundover bit set up as a .5 inch endmill.

I did an inside pass for the handle and an outside pass for the profile of the board at .125 inch depth to round the top edges. I then offset the Plexiglas pocket inside by .002 inches and cut out the Plexiglas with a 1/16 inch endmill to cut the corners as tight as possible then filed them slightly to fit. I put 10 glow in the dark airsoft BB's inside and used super glue to attach the Plexiglas to the board.

Maze pattern from online Maze generator.


I changed a few things to make this cut faster. I changed the bit for the plexiglass recess to a 1" bit I use for my spoilboard clearing. Cut that time from over an hour to 6 minutes. (feedrate 35 ipm, plungerate 10 ipm, RPM 3850, depth per pass .425) This will allow for one pass of the pocket for the plexiglass. I also changed the maze cut start depth to the max depth of the pocket cut, otherwise you'll just watch the 102 bit cut for .1 of an inch and cut air only. I increased the feeds and speeds as well (with my experience, the MDF can handle it without breaking. I changed the depth per pass to .1) This made for a total cut time of less than 2 hours, where it was well over 6 prior. Other then that, this is a great file!

How did you go from the maze file to Carbide Create or similar?

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