I built this custom illuminated wall art of Maui to run through the complete workflow of vector design, CNC routing, and LED integration. The final piece combines multi-tool CNC machining, V-carve engraving, and hidden LED backlighting into a clean, flush-mounted sign.

CAD & Vector Design

The design started in Inkscape, where I manually traced a raster map of the island to get an accurate vector outline and integrated the typography. I exported the clean SVG and pulled it into Autodesk Fusion 360 as a base sketch.

After cleaning up the stray spline nodes, I used Fusion’s parametric tools to extrude the 3D body and cut a rear internal channel. This channel houses the LED lighting strip and wiring harness so the sign can sit perfectly flush against the wall.

CAM & CNC Machining

I programmed the CAM toolpaths in Fusion 360 and ran them on a Shapeoko 3 XXL CNC router using MDF stock. The build required three distinct operations:

  • Engraving: I used a 90-degree V-carve bit for the text and geographic markers to get sharp, clean line-width variations based on depth.
  • Pocketing: I ran a 1/8-inch flat end mill to clear out the rear trench for the LED strip.
  • Profiling: I cut the final outer contour using a 1/4-inch flat end mill, adding tab supports to keep the part from shifting during the final pass.
Shapeoko 3 XXL cutting the MDF stock

Running the multi-tool CAM operations on the Shapeoko 3 XXL CNC router.

Assembly & Hardware Integration

To get the sign to sit completely flush against the wall, I used a manual mill to cut a couple of keyhole slots into the back of the MDF. For the lighting, I press-fit an LED strip into the CNC-routed rear channel and soldered the leads to a standard DC barrel jack, giving it a clean connection point for the power supply.

Project Wrap-Up

Finished illuminated CNC-routed sign of Maui, Hawaii

The completed sign with edge-diffused LED backlighting and V-carved text.

This piece was a great exercise in running a complete vector-to-CNC workflow. A few practical takeaways from the build:

  • Toolpath Sequencing: Running the delicate V-carving before the heavy contour profiling minimized tool deflection and kept everything aligned.
  • Feeds and Speeds: Dialing in the spindle RPM and feed rates for MDF kept the edges from burning and left a clean surface finish.
  • Z-Zeroing: Setting up a reliable Z-zeroing workflow during tool changes was critical to prevent depth offsets between the engraving and pocketing passes.