The Timeless Craft of Plywood: A Deep Dive into Materials & Building Techniques

Corrine Lombardo
May 1
5 min read

For thousands of years, woodworking has been a cornerstone of craftsmanship, evolving with technological advancements yet often sticking to tried-and-true methods. At Raleigh Woodworks, we embrace this legacy by combining time-tested building techniques with modern materials that enhance durability and design. One such material—plywood—has a fascinating history and continues to be a superior choice for custom cabinetry and built-ins.

The History of Plywood: 3000 Years of Innovation

Plywood’s origins date back to ancient Egypt, around 1500 BCE, where thin layers of wood veneer were glued together to create stronger, more stable surfaces. This early version of plywood allowed Egyptian craftsmen to maximize the use of valuable hardwoods while ensuring strength and stability in furniture and architectural elements. The method of cross-laminating wood layers prevented warping and added durability, setting the foundation for modern plywood.

Egyptian Watercraft Plywood — Egyptian Watercraft - Ovedc, CC BY-SA 4.0. https://creativecommons.org/licenses/by-sa/4.0, via Wikimedia Commons

The Greeks and Romans later adopted and refined this technique, using layered veneers in furniture making and decorative arts. Roman builders used early forms of laminated wood in shipbuilding, recognizing its strength and flexibility.

During the 18th and 19th centuries, European furniture makers began experimenting with more sophisticated veneering techniques, leading to the use of plywood-like materials in decorative furniture. However, it wasn’t until the Industrial Revolution that plywood truly transformed. The invention of rotary-cutting lathes allowed for the efficient production of thin wood sheets, making plywood more accessible and cost-effective.

In 1865, American inventor John K. Mayo patented one of the first modern plywood designs, followed by the development of waterproof adhesives in the early 20th century. This innovation paved the way for plywood’s widespread use in construction, shipbuilding, and furniture making. By World War II, plywood was a staple in military applications, valued for its strength-to-weight ratio and versatility.

Today, plywood remains a go-to material for furniture makers and builders worldwide. Its ability to resist expansion, contraction, and warping makes it ideal for large pieces and built-ins—especially in environments prone to humidity fluctuations.

Why We Use Plywood: Stability, Strength, & Versatility

At Raleigh Woodworks, we prioritize materials that balance beauty with function. Plywood offers the ideal combination of stability and strength while allowing for a wide range of design possibilities.

Resistance to Humidity & Expansion: Unlike solid wood, plywood’s cross-grain structure resists seasonal movement. This makes it less likely to warp or crack, a critical feature for large built-ins or cabinetry.
Durability in Large Builds: Plywood provides the strength needed for expansive surfaces without the weight or instability of solid wood.
Cost-Effective Without Sacrificing Quality: While still a premium material, plywood allows for efficient use of wood resources, making it a smart choice for both budget and design.

Material Spotlight: Our Plywood Selections

We source high-quality plywood tailored to each project’s needs:

For Painted Pieces: We use Baltic Birch plywood with poplar faces, offering a smooth, even surface perfect for paint. Its dense core ensures durability and prevents warping over time.
For Stained Pieces: Our most common plywood choices for stained finishes include:
- White Oak – Known for its pronounced grain and durability.
- Red Oak – A cost-effective option with a warm, distinct grain pattern.
- Maple – Offers a smooth, tight grain ideal for modern, clean looks.
- Walnut – Valued for its rich color and striking grain.

While these are our most popular options, we can source other hardwood veneers upon request.

Plywood, MDF, HDF & Solid Wood: Making the Right Choice

Plywood, MDF (Medium Density Fiberboard), HDF (High-Density Fiberboard), and solid wood each have their place in woodworking, and understanding their strengths and weaknesses is crucial for selecting the right material.

Plywood: A highly versatile and durable material, plywood offers superior structural strength and is less prone to warping, making it ideal for large builds and pieces exposed to fluctuating humidity. Thanks to its cross-laminated structure, plywood maintains stability over time while providing strength without excessive weight. It’s commonly used in custom cabinetry, built-ins, and furniture frames where strength and longevity are key. Plywood is also celebrated for its aesthetic flexibility—designers often leave the layered edges exposed as a design element, as seen in iconic mid-century modern pieces by Charles and Ray Eames.
MDF: While incredibly stable and smooth—perfect for painted pieces—it reacts poorly to water and humidity, making it unsuitable for certain applications. However, MDF shines in specific scenarios. For example, when creating raised panel doors or drawer fronts, MDF is the preferred material because it avoids the exposed plywood lines that would appear when using a router to plunge into plywood. Its consistent density allows for crisp, clean router cuts without the risk of splintering.
HDF (High-Density Fiberboard): Similar to MDF but denser and stronger, HDF provides an even smoother surface and is more durable for high-impact areas. It’s often used for cabinet door panels, drawer fronts, and furniture components that require a flawless finish. HDF’s density also makes it more resistant to dents and dings, which is ideal for pieces that will see frequent use.
Flat Grain Solid Wood: In certain applications, flat grain solid wood is preferred for its natural beauty and strength. However, it is more susceptible to expansion and contraction due to humidity. At Raleigh Woodworks, we use flat grain solid wood for parts like cabinet faces, where the aesthetic of natural wood is essential. Our cabinet faces are typically made from Poplar 3/4" x 1-1/2", allowing us to avoid edge banding and providing a seamless, durable finish.

At Raleigh Woodworks, we carefully consider the best material for each part of a build, using MDF, HDF, plywood, and flat grain solid wood strategically where they offer the most benefits, ensuring a balance of aesthetics, durability, and functionality.

veneer and plywood making — **Veneer and Plywood Making - Vermont, National Forest Service photograph.** https://itoldya420.getarchive.net/media/veneer-and-plywood-making-vermont-911798

The Science Behind Plywood’s Strength

Plywood’s cross-grain construction is key to its durability. By alternating the grain direction with each layer, the natural tendency of wood to expand and contract is minimized. This layering technique not only adds strength but also creates a material that’s less likely to warp over time.

Flat Grains vs. Cross Grains: Solid wood with flat grain tends to expand and contract more dramatically with humidity changes, while plywood’s crisscross structure neutralizes these movements.
Layer Count & Thickness: The more layers in a plywood sheet, the stronger and more stable it becomes. High-grade plywood used in cabinetry often has more plies, increasing its resistance to warping and bending.
Adhesive Technology: Modern adhesives used in plywood manufacturing are engineered for strength and water resistance. These adhesives bind the layers tightly, ensuring the entire panel acts as a single, unified structure.
Pressure & Heat Bonding: During manufacturing, high heat and pressure are applied to compress the veneers and adhesive, creating an incredibly strong bond that enhances the plywood’s load-bearing capacity.

This combination of materials, layering, and precision manufacturing makes plywood one of the most reliable choices for furniture and cabinetry, especially in environments where temperature and humidity can fluctuate.

Sandakan Sabah Plywood-Factory. Photo by CEphoto, Uwe Aranas. https://commons.wikimedia.org/wiki/File:Sandakan_Sabah_Plywood-Factory-24.jpg

A Material That Stands the Test of Time

Plywood’s legacy in woodworking is a testament to its versatility, durability, and the craftsmanship it supports. Its ability to bridge ancient techniques with modern needs makes it a cornerstone material in many of our most complex and beautiful builds at Raleigh Woodworks.

At Raleigh Woodworks, we are committed to creating custom pieces that blend function with beauty, using materials that ensure longevity and timeless appeal. Whether you’re envisioning a custom built-in, a handcrafted dining table, or elegant cabinetry, our careful selection of materials ensures a finished product that’s not only stunning but built to last.

Our commitment to craftsmanship means every piece is built with care and precision, using materials that enhance both design and durability. Plywood isn’t just a component in our process—it’s a foundation for creating pieces that will stand the test of time.