How to Cut Composite Shelving
The word "composite" refers to a range of materials manufactured by combining wood chips and glue. One of the most common composite shelving materials is medium density fiberboard (MDF), either finished or unfinished; another common one is melamine, which is basically particle board enclosed in a plastic casing. Cutting composite shelving almost always causes chipping on the surface, reports Carbide Processors Inc., but you can minimize and even avoid the damage with the right tools and techniques.
The Right Tools
Whether you're crosscutting premade composite shelving with a circular saw or ripping the shelves from a sheet of composite material on a table saw, you need the right blade. It should have a minimum of 80 teeth and be as sharp as possible. Your saw blade for melamine must be accurately aligned with the foot of the saw or the table, and the cutting depth no more than 1/2 inch deeper than the thickness of the material you are cutting.
When using a jigsaw or reciprocating saw to cut curves, use a new metal-cutting blade rather than an all-purpose wood-cutting blade. Bob Vila recommends scoring the shelving first using a utility knife or box cutter.
Crosscutting the Shelving
When crosscutting shelving, it's important to make square cuts, or the shelves will form gaps at the corners of the cabinet or wall. Marking the length of the shelf, lining up a carpenter's square on the mark and drawing a line with a pencil give you a reliable reference for the cut. You can minimize chipping to the visible side of the shelf by marking the line and making the cut on the opposite side of the shelf.
You can also make an accurate crosscut by using the crosscut guide on a table saw. When cutting on a table saw, the visible side of the shelf should be facing up.
Cutting Curves or Notches Instead
As with cutting straight lines, you can avoid chipping the surface when cutting curves or notches with a jigsaw by doing it from the back. Because this technique involves making measurements that are the reverse of the ones you need, however, it can be confusing.
An alternative method is to lay masking tape over the area of the shelf where you need to make your cut. You then make your mark on the tape and cut right through it. Peeling off the tape after the cut is complete should reveal a chip-free surface.
Two Visible Sides
You can use masking tape to minimize chipping if you have to make a straight cut and both sides of the shelf will be visible. Simply lay the tape along the path of the cut and cut through the tape. If you're cutting on a table saw, set the cutting depth of the blade to about three-quarters of the thickness of the shelf. Make one straight cut, then turn the shelf over and run it through the saw again. If the blade is sharp, well aligned and doesn't wobble, you should find a minimum of chipping on both surfaces.
Chris Deziel is a contractor, builder and general fix-it pro who has been active in the construction trades for 40 years. He has degrees in science and humanities and years of teaching experience. An avid craftsman and musician, Deziel began writing on home improvement topics in 2010. He worked as an expert consultant with eHow Now and Pro Referral -- a Home Depot site. A DIYer by nature, Deziel regularly shares tips and tricks for a better home and garden at such sites as Family Handyman, Hunker.com, and SFGate Home Guides.