.png){kind=spacer}
How to Make a 6-Foot Growth Chart on a 4-Foot CNC
- 14 hours ago
- 3 min read
Solving Real-World CNC Challenges with Smart Setup & Simple Techniques
One of the most exciting parts of owning a CNC isn’t just what it can do—it’s what you can figure out how to make it do.
In this project from the Johnsonville Woodworker, a simple request turned into a great example of problem-solving:
How do you cut a 6-foot growth chart on a 4-foot CNC?
Let’s break down how this project came together—and how you can apply the same approach on your own Onefinity CNC.
The Project: A Custom Growth Chart
The goal was straightforward:Create a clean, engraved wooden growth chart from a design file (sourced from Etsy), using a standard pine board.
Material: Clear pine board
Length: 6 feet
Tooling: 1/8" straight flute bit
Machine: 4-foot CNC
Simple—until you realize the board is longer than the machine’s cutting area.
The Challenge: Cutting Beyond Your Machine Size
This is a common situation for CNC owners. Your machine might be incredibly capable—but physical size limits still exist.
Instead of stopping there, this project used a tiling-style workflow:
👉 Cut one section👉 Reposition the board👉 Cut the second section perfectly aligned
This is exactly the kind of flexibility that makes CNC such a powerful tool for real-world projects.
Step 1: Rethinking Your Zero Point
Most users default to setting zero at the front-left corner of the material.
For this project, that wouldn’t work.
Instead:
Zero was set at the back of the machine
The first cut was run in reverse orientation
This allowed the second half to align when the board was flipped
This simple shift in thinking is what made the entire project possible.
Step 2: Using Alignment Pins for Repeatability
Consistency is everything when you’re repositioning material.
To ensure perfect alignment:
Pins were installed in the spoilboard
The board was indexed vertically along the Y-axis
Clamps were added to secure everything in place
This created a reliable reference system for both cuts.
Step 3: Air Cuts = Confidence
Before committing to the cut, an air test was run:
Bit raised ~1 inch above the material
Full toolpath simulated
Visual alignment confirmed
This step is often skipped—but it’s one of the easiest ways to prevent costly mistakes.
Step 4: Cut, Reposition, Repeat
After completing the first half:
The board was removed
Stops were repositioned
The board was flipped
Zero was reset using a touch probe
Another air test confirmed alignment before running the second cut.
Step 5: Clean Results with Simple Tooling
The project used a 1/8" straight flute bit, which worked well for detail—but came with one tradeoff:
Sawdust packed into the engraved grooves
A quick cleanup solved that easily, and the final result turned out clean and precise.
Step 6: Finishing Touches
To wrap things up:
Edges were softened with a round-over bit
The board was left unfinished so the customer could customize it
The final product?A clean, professional-looking growth chart—made on a machine technically “too small” for the job.
Why This Matters for CNC Owners
This project highlights something we emphasize all the time at Onefinity:
Your CNC is more capable than you think.
Even with a smaller machine like a Woodworker or Journeyman, you can:
Tackle oversized projects
Use tiling techniques for extended cuts
Build products with real commercial value
Turn Small Machines Into Big Opportunities
Projects like this aren’t just fun—they’re practical.
Growth charts, signs, furniture components, and long panels are all:
High-demand products
Easy to customize
Perfect for small business production
And the best part?You don’t need a massive industrial machine to do it.
Final Thoughts
This was a first-time technique for the creator—and it worked beautifully.
That’s what CNC is all about:
Trying new things
Solving problems
Expanding what your machine can do
If you’ve ever thought “my machine isn’t big enough for that”—this is your reminder:
👉 It probably is. You just need the right approach.
Build more. Learn more. Create without limits.
