Custom Fabrication - Services
Windhover Studios combines technology and hand crafting to provide custom fabrication services. We use computerized machinery (CNC routing) to cut 2D and 3D shapes to customer specifications. Solid wood is the material we usually use, but we can fabricate products from other materials, such as plywood, fiber board, structural foam, or some metals. We offer fabrication services as one step in a customer’s overall process, but also execute commissions for finished custom products. We complement the machine fabrication with hand crafting to refine and finish surfaces and to create the desired final appearance of the product.
Custom Fabrication – Services - Engraving
Windhover Studios engraves lettering and designs in wood and other suitable materials. This service is usually used to produce signs and plaques. Using a process known as V-carving, we cut letter patterns into the material to simulate the crisp, three-dimensional look of hand carved lettering, but at a more accessible price.
Engraved wood without paint
An example of engraved signs before painting shows the 3-dimensional quality of the lettering achieved by the V-carving process. Size: 36” X 24”. Material: Philippine mahogany.
Engraved wood sign
Graphic designs and logos can be incorporated in engraved signs. In this example, the machine-carved tree design of the logo was accentuated by hand carving the texture of the background. Size: 34” X28”. Material: quartersawn white oak.
Custom Fabrication – Services - Computerized Cutting and Shaping
Windhover Studios custom cuts 2D shapes and carves 3D shapes using computerized (CNC routing) technology. Starting from computer graphic files, pictures, or hand-drawn sketches, we develop computer designs (CAD files). The CAD files provide the basic information to guide the cutting by the CNC router. We also have a probe that can digitally scan the outline of a 2D shape or the surface of a 3D shape to create the CAD file. This is valuable for reproduction of an existing object.
Original corbel on house, showing deterioration and missing parts
David Mobley and Howard Mittleman holding two of the finish-carved corbels prior to installation
Finished restoration, showing new corbels installed and painted
In this project, CNC shaping was used to reproduce elaborately carved corbels as part of the architectural restoration of a Victorian-era house by North River Boatworks (Howard Mittleman, owner). The original corbels were badly deteriorated, but a combination of digital scanning and computer design work was used to construct the CAD model of the corbels. The bulk of the carving was done by the CNC machine, but the final carving was intentionally left to be finished by hand. The hand carving allowed for freedom of expression in producing details such as veining in the acanthus leaf design. It also led to subtle variations among the individual corbels, so that the overall effect was more pleasing than if the corbels were completely identical. By combining computer-controlled machining with hand carving we were able to deliver finely crafted corbels for the architectural restoration in a timely manner.