Should I use a straight inlay, a stepped inlay, a V inlay or an epoxy fill for my design?

What each method is good at

Straight inlay (Inlay Toolpath, Male Straight plus Female Pocket or Hole). Vertical walls, same end mill both sides. Every inside corner of the pocket carries the bit radius, and the software rounds the matching outside corners of the insert. Best for large geometric shapes, borders and bold letters where rounded corners are acceptable. Fewer variables than a V inlay, and the insert can be thick.

Stepped inlay (Male Stepped). Built for push-through letters and shapes that are inserted from the back of a sign. Step Depth is the height of the step measured down from the Start Depth, and Step Width is how far outside the vector the shelf extends. The shelf hides behind the sign face and gives a mounting surface. Leave room between neighboring shapes for the step.

V inlay (VCarve Inlay toolpath). Tapered walls from a V bit, so corners come out sharp and the plug wedges tight as it seats. Best for text, logos and detailed art. It needs more setup care and a plug backer that must be cut away afterward.

Epoxy fill. Carve a pocket and pour color. One published guide rates it the easiest and fastest, with unlimited colors, and gives 1.5 to 2 mm as the minimum depth for solid color, a sealer coat first to stop wicking into the grain, and 24 to 72 hours of cure before sanding. Epoxy is softer than hardwood, so sand with a flat block to avoid dishing.

How to choose

1. Sharp inside corners or fine serifs: V inlay, or epoxy.
2. Big simple shapes, thick wear layer wanted: straight inlay.
3. Letters lit from behind or mounted through a face panel: stepped inlay.
4. Hairline detail thinner than a wood plug can survive, or many colors: epoxy.
5. Wood grain and natural contrast matter (maple in walnut is the classic pair): wood inlay.

Pro tips

• Wide wood inlays can crack later from seasonal movement. The same guide suggests matching grain direction and keeping inlay width under about 2 inches.
• Whatever you pick, run a coaster-sized rehearsal in the same species first.
• See the entry on epoxy inlay fills for the pour workflow, and the entry on smallest inlay detail for line-width limits.