How to Make a 6-Foot Growth Chart on a 4-Foot CNC

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How to Make a 6-Foot Growth Chart on a 4-Foot CNC

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:

:backhand_index_pointing_right: Cut one section​:backhand_index_pointing_right: Reposition the board​:backhand_index_pointing_right: Cut the second section perfectly aligned

This is exactly the kind of flexibility that makes CNC such a powerful tool for real-world projects.

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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:

  1. The board was removed

  2. Stops were repositioned

  3. The board was flipped

  4. 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.

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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:

:backhand_index_pointing_right: It probably is. You just need the right approach.

#TeamOnefinity

Build more. Learn more. Create without limits.

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