How to Cut MDF Using 4 Different Tools

When working with wood, there’s a strong possibility you’ll come across a medium-density fiberboard (MDF). Typically, you can find MDF in various bedroom pieces and cabinets, and even in the occasional kitchen countertop. This material is challenging to cut through, so carpenters utilize various methods to get the job done.

One common and simple way to cut MDF is with a circular saw. While this method is fast, I don’t recommend it because it is not as accurate. There are other methods that will produce better results.

If you do decide to use a circular saw, make sure to use a good circular saw guide rail to make the cuts a bit more precise.

In this article, I’ll look at four techniques to cut through MDF.

How to Cut MDF Using a Table Saw

Similar to making other wood cuts, you can cut MDF with a table saw. This is the quickest way to cut MDF, provided you own a table saw.

Tools Required

• Table saw with a carbide-tipped blade
• MDF sheet
• Safety glasses
• Dust mask
• Earmuffs

Position the MDF on the outside of the saw blade so that you can use both of its sides. For instance, suppose you’re cutting a 12-inch wide board. You can adjust your table saw fence to measure 11 ½ inch-wide.

Next, flip your MDF over and run it through the machine again to make another 11 ½ inch board. As a result, you’ll be able to make the most out of the board.

Before you dive into cutting with a table saw, make sure to review all of the safety requirements. Table saws are dangerous – don’t skip this step.

Here are the steps to follow for your cuts:

• Position Table Saw Blade: You need to position the MDF on the table saw so that the blade is positioned higher than the MDF height. Anywhere around 1/16 of an inch above the MDF will allow the blade to fully cut through.
• Set the Table Saw Fence: Line up your fence along the workpiece. This causes the gauge to glide along the fence as you cut, preventing tear-out on the final edges of your cut piece.
• Make Your First Cut: Move the board slowly towards the blade and start cutting. Allow at least 2 inches between the piece and the final cut you want. You’ll need this space to cut off chipping around your board’s edge after each cut.
• Check for Chips or Rough Edges: After each cut, inspect the sides and bottom of the board for rough edges or chipping. You may touch the edges with your hands, to be sure. If you find any rough parts, use your table saw to trim it off or smoothen it using sandpaper.

Cutting MDF, also called hardboard, with a table saw is perfect if you have a lot of cuts to make. Once you get your angles and position set up, you can quickly move through different cuts.

How to Cut MDF Using a Router

If you don’t have a table saw, another power tool capable of cutting MDF well is a router.

Tools Required

• Router (carbide flute bit if possible)
• Router bit (straight or other)
• MDF board

Routers come in numerous types and sizes. Which one you use to cut MDF will depend heavily on the project. You may also use a standard router with a straight bit or invest in a more versatile plunge router with various bits.

As with all power tools, practice caution when using a router to avoid injury. 

• Put on your safety gloves and glasses.
• Place your workpieces on the workbench and lock them tightly to prevent them from moving as you work. You may use a clamp to fasten the workpiece.
• It’s best to use a carbide flute bit router as it has more cutting edges and will enable you to cut smooth and straight edges.
• Set your router bit’s depth of cut to match the thickness of your MDF piece. For example, if you’re cutting ½-inch MDF, adjust your router bit to cut ½-inch deep on each pass.
• Hold the router firmly and turn it on. Make repeated passes with the router bit until you cut through all MDF pieces.
• You want to cut each piece slowly since MDF has a lot of resin and fibers that may damage the bits and make them blunt.
• Be prepared to smoothen the edges after cutting, especially if you plan to paint them, as they may be fuzzy and rough. 

It’s best to route MDF in small sections at a time. This is so you can go back over the same area until you reach the desired depth. As a result, your cut will be much cleaner and more precise.

When using a straight bit, making two or three passes (as mentioned above) is recommended to get a clean, straight cut with your router.

If you don’t have a good router, take a look at my best beginner router review.

How to Cut MDF Using a Hand Saw

The classic method for cutting MDF is using a hand saw. If you have a lot of MDF cuts to make, this can be time consuming and laborious. But, getting access to a hand saw is both cheap and easy.

Tools Required

• Hand saw
• MDF board
• Pencil
• Workbench
• Safety goggles
• Face mask
• Protective earmuffs

For rough cuts, you can use a hack saw. For more precise cuts, opt for a good coping saw.

• Place the MDF board on a flat surface such as a workbench.
• With a pencil, draw the line you want to cut across the face of the board. 
• Clamp a ruler or any other straight edge to the board next to this line in a way that won’t hinder the saw. The blade will also not turn as a result. 
• Place the blade of the saw against the board’s edge, aligned with the mark. Starting the cut perfectly straight is important, as any imperfection may mess up the whole cut.
• Start the cut at a high angle on either side to sink the teeth into the board. Gradually lower the blade after creating a deep enough groove that the blade can follow.
• Continue cutting as you push the blade along the clamped edge to ensure your cut remains straight.
• Once halfway down the cut, support the hanging end of the board to prevent it from breaking off. Then, slow down a bit to finish the cut smoothly.

Tips & Tricks

When cutting wood with a hand saw, it’s critical to cut precisely along the line. If you’re not careful, you’ll wind up with an uneven edge and may have to recut that section. 

When cutting at an angle with a handsaw, start by lifting the leading end of the handsaw off the wood and lowering it onto the wood to begin the cut. This will keep your hand saw from binding and causing backlash on the wood.

How to Cut MDF Using a Utility Knife

The advantage of using a utility knife as a cutting instrument over a saw or other power equipment is that it is safer. Also, using a utility knife does not require any specific skills or training, and anyone can use it with little chance of harm or mishap.

Tools Required

• Utility knife
• MDF board
• Tape measure
• Pencil

Before cutting, make sure you have a sharp blade. Dull blades make the cutting process much more difficult.

• Measure the Board Size: Start by measuring your MDF board with a tape measure and marking the key spots with a pencil. Then, to cut along the lines without missing them, make sure they are straight and distinct. I recommend using a T-square or carpenter’s square for this purpose.
• Cut the MDF: You can use a pointy utility knife to cut along the defined lines. When looking at the board from the side, score it lightly numerous times until you detect a groove that runs through the material. Next, press one side of the board until it snaps against the line. This happens swiftly and smoothly once you’ve established a groove.
• Clean Up Cuts: Continue cutting along your marks with the utility knife until the MDF is cut into the desired pieces. Keep in mind that it may require a bit of force and patience due to the sticky nature of MDF. Go back over your cuts with a fine grit sandpaper to remove any snags or chips.

While this process is the longest and most labor intensive of any I recommend, it is also the easiest. Even if you have no cutting experience before this, you can slowly cut MDF accurately.

Conclusion

With a bit of practice, these techniques can help cut the time it takes to make something with thin pieces of MDF. The best solution will be determined by how much time you have, the type of MDF board you use, and your prior woodworking skills. Also, to be safe, don’t forget to wear protective gear.