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How do I do epoxy inlay fills in carvings: workflow, bubbles, and the big gotchas?
Updated Oct 13, 20262 min readVCarve Pro & Aspire
The workflow
- Carve for epoxy: v-carve or pocket at least ~1/16 to 1/8" deep (deeper = richer color, more forgiving sanding). Flat-depth v-carves and pockets hold color better than knife-edge V bottoms.
- SEAL the carve first (critical): brush thin CA, dewaxed shellac, or a thin epoxy skim coat into the carved areas. Unsealed wood outgasses air into your pour = endless bubbles, and dark epoxy wicks into surrounding grain = fuzzy edges.
- Mix slow-cure epoxy (deep-pour or tabletop; slow cure sheds bubbles better) with pigment: mica powders, pigment pastes, or tints. Mix thoroughly but gently.
- Overfill slightly. Epoxy shrinks/settles, and a slight dome above the surface sands flush. Underfilled letters mean a second pour.
- Pop bubbles: pass a torch/heat gun quickly over the surface (seconds; heat thins it and bubbles rise), and repeat over the first hour.
- Cure fully (don't rush, because soft epoxy clogs abrasives and smears), then surface flush: either a shallow CNC skim pass (~0.1 to 0.2 mm, and re-zero on the material!) or sand through grits 120 to 220.
- Finish the whole piece. Note that epoxy sands cloudy/matte, and the final clear coat (poly/oil) restores its depth and gloss.
The gotchas
- Bleed into grain means you skipped sealing (step 2). Worst in open-grain woods (oak).
- Bubbles forever means unsealed wood outgassing or fast-cure epoxy in a deep pour.
- Cloudy after sanding is normal, and the finish coat fixes it. Cloudy underneath means moisture or a bad mix.
- The CNC skim pass beats hand sanding on big fills (flat, fast, no rounded edges), but only after FULL cure.
Pro tips
- Tape the board's back/edges, because epoxy finds every path off the workpiece.
- Test the pigment ratio on scrap, since colors shift as epoxy cures and again under finish.
- Combine with the flattening entry for the river-board/epoxy-slab genre.
Sources and further reading
Forum thread 28the software maker's forum (opens in a new tab)Master CNC Projects with Training from Learn Your CNC Academyacademy.learnyourcnc.com (opens in a new tab)Woodworking Tools for Beginners - Woodworking Techniquesidcwoodcraft.com (opens in a new tab)Still stuck? Ask the community
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