Using Tabs Effectively — Size, Placement, and Removing Them Cleanly
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Tabs hold parts in place during through-cuts. Too few and parts fly. Too many or too large and removal is a pain. Here's the balance.
Tab Sizing
| Material | Width | Height (remaining skin) |
|---|---|---|
| Softwood | 4–5 mm | 1.5–2 mm |
| Hardwood | 5–6 mm | 1.5 mm |
| Plywood | 4 mm | 1.5 mm |
| MDF | 4 mm | 1.5 mm |
| HDPE/Acrylic | 4 mm | 1 mm |
| Aluminum Composite | 4 mm | 0.5 mm |
Thinner tab height = easier removal. Thicker = more secure. Find the balance per material.
Tab Placement Rules
- Minimum: 2 tabs per part
- Small parts (< 100mm): 2 tabs on opposite sides
- Medium parts (100–300mm): 4 tabs (corners or midpoints)
- Large parts (> 300mm): Every 100–150 mm of perimeter
- Always tab corners on rectangular parts — corners lift first
Placing Tabs in Vectric Aspire
In the Profile toolpath settings:
- Add Tabs → check the box
- Set tab width and height
- Aspire auto-places tabs or let you click to place manually
- Manual placement is worth the extra minute — avoid tabs on curved features you care about
Removing Tabs
Flush-trim saw or Japanese hand saw: Best method — thin kerf, cuts flush.
Oscillating multi-tool: Fast but can overshoots easily — tape around the tab area first.
Chisel: Good for hardwood tabs — pare flush to surface.
Avoid: Box cutter (tears grain), reciprocating saw (too aggressive).
After Tab Removal
Sand the tab witness mark flush with 80 grit, then finish sand with your normal progression. On V-carved signs where tabs are on the back, nobody sees them — don't over-sand.