How do I make a carved wooden flag: the union, stars, and stripes workflow?

The standard build (flat flag)

1. Stock: glued panel (pine boards for the rustic torched look; hardwood for premium), typically ~19.5×37" for the classic 50-star proportion (union = 40% of length, 7/13 of height). Flatten/skim if not true.

2. Design in the software:

• Draw the flag rectangle; 13 stripes = Array Copy of one stripe vector
• Stripes: the grooves between stripes are Profile-ON lines with a 90° v-bit (~0.1 to 0.15" deep), or v-carve the alternating stripes' full fields shallow for a two-level look
• Union: Pocket the union field down ~0.1 to 0.25" (or leave it proud and pocket around, two schools), then v-carve the 50 stars INTO it for the classic look. Star vectors: draw one star, Array Copy 6×5 + 5×4 offset grids. Raised stars (pocket around them) look amazing but take much longer (see the raised-letter entry for the technique).
• Optional: v-carved dedication text on a lower stripe

3. Toolpaths in order: union pocket → star v-carve → stripe grooves → any text → Profile cutout. Two tools total (end mill + 90° v-bit) keeps it simple.

4. The finishing (where flags are won):

• Torched: scorch the whole face (propane torch), wire-brush, then sand the SURFACE lightly. Char stays in the carves as natural black detail. Fast, forgiving, best-seller look.
• Painted: the two-color workflows: stain everything, paint-fill union field blue + stripes red via mask (see the paint-fill entry), or base-coat + dry-roll for raised versions
• Rustic + paint combo: whitewash/red stripes over torched wood
• Exterior topcoat if it's going outside (spar urethane), and see the HDU entry for the truly weatherproof version

The wavy upgrade (3D)

A "waving" flag is the flat design projected onto a wavy 3D surface. Model the wave (in Aspire: Create Shape from wavy cross-sections or Two Rail Sweep, which are Aspire only; in VCarve Pro, import a wavy-flag STL as your one third-party model), then use the Project toolpath onto 3D Model option in the V-Carve and Profile toolpath forms for the stripes/stars, and 3D Roughing/3D Finishing for the surface. Machine time jumps accordingly.

Pro tips

• Star field spacing is the visual make-or-break. Use the real 6/5 alternating grid, and don't eyeball.
• Char + carve = smoke smell in the shop for days, so torch outside.
• Trademark-wise, the US flag itself is public domain, but unit insignia and military emblems are NOT. Keep those off commercial flags without a license.