Learning How to Create Wood Inlays with Ease

Inlay of Bear feet on Sycamore Wood

Adding an inlay to a wood project instantly separates it from the ordinary. A simple cutting board, box lid, or tabletop becomes custom. It becomes personal. And in many cases, it becomes higher value.

Inlays aren’t complicated — but they do require the right tools, patience, and a clear process.

Let’s break it down step by step.

1. Start With the Right Tools

Before you even design the inlay, take stock of what you already own.

You can create inlays using:

• A CNC machine (if you’re lucky enough to have one — it does most of the precision work for you)

• A plunge router

• A trim router

• A scroll saw (for template creation)
  

I own a large plunge router with a ½-inch chuck, but I’ll be honest — I don’t always feel comfortable controlling it for detailed inlay work. Instead, I prefer using a trim router with a ¼-inch chuck fitted with a plate that has handles. The lower speeds and lighter feel give me much more control.

I own both a RIDGID trim router and a Bosch trim router. Both perform extremely well. I generally choose corded tools over battery-powered — I don’t like managing multiple batteries and charging cycles when I’m in the middle of a project.

2. Create or Purchase a Template for Wood Inlays

Every inlay starts with a template.

You can:

• Purchase a pre-made template

• Create your own using a scroll saw

• Generate one from a JPG or SVG file

If I’m designing something custom, I’ll convert a JPG or SVG file into a scroll-saw-friendly template. The key is choosing a design that:

• Is simple enough to cut cleanly

• Has enough interior space for your router bit to maneuver

• Doesn’t include details too fine for your blade

If the blade can’t physically fit, the design won’t translate well to wood.

Two places to purchase ready-made templates is Jeff Mack Supply and Crafted Elements which are both Canadian businesses.

3. Use the Correct Router Bits and Bushings

Precision here matters.

You’ll need:

• The appropriate router bit

• Copper guide bushings that attach to your router plate

• A compatible router plate
  

I personally use SpeTool router bits. They’re reasonably priced and very durable. You can purchase them through Amazon or directly from their Canadian website. While manufactured in China, I’ve used them for years without issue.

Are there more expensive bits available? Yes. Have I needed them? No.

Choose quality, but you don’t need to overspend when you’re starting out.

4. Securing the Template and Routing the Inlay

Here’s the process:

1. Attach your template to the wood using double-sided tape.

2. Install the correct-sized copper bushing on your router plate.

3. Match your router bit to your template and bushing size.

4. Carefully route out the design.
   

If you plan to fill with epoxy, route down approximately ¼ inch.

If you want a subtle engraved look, you can keep the depth shallow — just enough to define the shape — and then apply oil instead of epoxy.

Take your time here. Control is more important than speed.

5. Filling the Inlay With Epoxy

For shallow inlays (around ¼ inch), you can use art or tabletop epoxy resin.

I personally use Magic Resin. It’s a Canadian company, and they produce both Art Resin (for shallow pours) and deep pour resin for larger projects. I use both depending on the application.

A few important tips:

• I always use powdered pigments. Liquid dyes can stain surrounding wood. Powders do not.

• You need very little pigment for strong colour.

• A full colour set is reasonably priced and lasts a long time.

• Allow at least 24 hours before sanding.

  
  

I tend to slightly overpour the epoxy. Once cured, I run the board through the planer to level it, then sand up to 400 grit for a smooth finish.

6. Finishing the Project

The finish depends on the purpose.

For food-safe projects like cutting boards:

• I use Walrus Oil board oil, which contains coconut oil, mineral oil, beeswax, and vitamin E.

• They also produce a wax that adds additional protection.

For decorative or non-food items:

• I use Varathane for durability.
  

Always match the finish to the function.

7. Why Add Inlays?

Inlays elevate your work.

They:

• Make projects more personal

• Add contrast and visual interest

• Increase perceived value

• Allow for customization (names, logos, shapes, themes)
  

A simple board becomes a wedding gift. A box becomes a keepsake. A tabletop becomes a statement piece.

Custom Inlays Available

We are happy to customize your projects with inlays.

To get started, we’ll need a high-quality JPG or SVG file that is suitable for routing and template creation. The design must be appropriate for blade width and routing clearance to ensure a clean result.

Inlays aren’t difficult once you understand the system: template, control, depth, fill, finish.

Master those steps — and you can turn almost any wood project into something unique.