Curved Designs Are Hard to Build—Here’s How to Make It Easier.

From fluid interiors to grand archways to sweeping façades, today’s architecture is embracing motion, softness, and complexity with curved designs. Curves evoke emotion, guide flow, and break the boxy monotony of traditional forms. 

But while designing curves is easy on paper (or screen), building them in the real world? That’s a different story.

Let’s explore why curves are often the first thing value-engineered out of a project—and how Kerfkore is changing that reality for architects, designers, and fabricators alike.

The Reality Check: Why Curved Designs Are Often Compromised

Whether you’re an architect, interior designer, or project manager, you’ve probably experienced this:

1. You present a stunning concept with a dynamic, curved focal point.
2. The client loves it. So does the design team.
3. Then it hits the fabricator’s desk—and suddenly, it’s too expensive, too complicated, or too time-consuming.

Why does this happen?

1. Time-Intensive Fabrication

Traditional methods such as kerf-cutting, steam bending, or CNC layering take serious time. Shops must build custom jigs, test radii, and manually finesse every bend. And if you’re using Luan plywood, you’re dealing with quality issues that just lead to frustration and a pile of scraps at the end. One mistake, and the whole panel may need to be redone. 

2. High Material Waste

Materials like plywood or standard MDF aren’t designed to bend easily. Even with kerfing or steaming, you’re working against the grain—literally.

This often results in:

• Cracked panels
• Broken boards 
• Split faces or delamination
• Unusable offcuts

This not only wastes wood or substrate, but also adds up in glue, fasteners, and shop labor. Even experienced teams frequently end up discarding materials mid-process when the results don’t match the intended curve.

And all that waste? It adds to the budget. 

3. Cost Overruns

More labor = more money. Between shop time, rework, CNC rentals, and materials, fabricators often pad bids for curved components—or steer projects away from them entirely.

Key cost drivers include:

• Labor Hours: Fabricators must spend significant time preparing, bending, clamping, and adjusting each panel.

• Rework: If the curve fails—or looks wrong once installed—it may need to be entirely redone.
• Extra Margin Padding: Because curves are unpredictable, many shops quote high to protect themselves from the inevitable pain points.

This leads to bloated bids or curved components being value-engineered out of the final design.

4. Quality Inconsistency

The final challenge? Even if the time, material, and budget hurdles are cleared, achieving precision and consistency in curved components is extremely difficult without the right materials.

Shops using manual or improvised methods face common issues:

• Irregular radii: It’s hard to maintain the exact curve multiple times over.
• Visible imperfections: Seams, ridges, and finishing issues often show through after lamination or paint.
• Mismatch between units: When curves are built by hand, they’re almost impossible to replicate perfectly across multiple panels or projects.

This inconsistency leads to friction between designers and fabricators, and ultimately, frustrated clients.

The Solution: Kerfkore Makes Curves Easy

Imagine achieving graceful, reliable curves—without bending over backwards. That’s exactly what Kerfkore delivers.

Kerfkore’s flexible panels are designed to bend easily and predictably, giving design professionals the freedom to dream big without fearing the build.

Here’s how Kerfkore solves the biggest curve fabrication challenges:

Saves Time

Kerfkore panels come pre-kerfed, allowing for immediate flexibility right out of the box. No special jigs, no trial-and-error, and no lost hours on manual labor. Fabricators can bend, glue, and install in a fraction of the time compared to traditional methods. Plus our panels require little to no sanding, patching, or use of putty/Bondo. 

Plus, it’s easy to finish the panel. Depending on your selected panel, you can paint, stain, or attach high-pressure laminates, veneers, and other semirigid materials for a finished result. 

“We saved about four days worth of labor on a recent project by using Timberflex (Over a 70% reduction). Not only did we produce a cleaner product, but we were able to move on to the next project ahead of schedule. We used to kerf our own boards, something that takes time and requires very little skill. Kerfkore Products allowed us to remove this step and focus our skills where they are really needed.”

MICHAEL PHILLIPS | MID-AMERICAN PRECAST INC. 

Reduces Material Waste

Because Kerfkore panels are engineered specifically for curved applications, they don’t crack, snap, or delaminate. You get smooth, consistent bends without waste—saving both money and frustration. 

“While we have made curved pieces with bending board and veneers previously, this was our first attempt at building something with this kind of shape. I found the Kerfkore to be easier to work with than I expected. I don’t know if I could have or would have wanted to build this the old way. We added additional supports inside which I understand is overkill with Kerfkore. I would feel comfortable doing more shapes with Kerfkore in the future.”

BRYAN EADS | THE BOOKCASE PLACE OF RICHMOND, INC.

Lowers Cost

Time is money—and Kerfkore saves both. Yes, pre-fabricated panels might seem more expensive at the get-go. But hand kerfing, working with plywood, or using a CNC machine can quickly add up the cost of projects. 

Plus, the predictability of the material reduces risk and rework, which helps keep bids competitive and projects profitable.

“The Kerfkore product line allows our team to focus on what they are really good at doing, rather than dedicating an excessive amount of wasted time on unskilled administrative tasks such as sanding, filling flat areas with Bondo and unnecessary framework. This allows us to offer a better price to our customers.”

WALTON SCOTT | QUALITY CABINET & FIXTURE COMPANY 

Delivers Premium Quality

Kerfkore doesn’t just bend—it bends beautifully. Smooth, repeatable curves mean less finishing work and more design fidelity. Whether it’s a dramatic ceiling wave or a subtle reception desk curve, Kerfkore helps bring the design vision to life with precision and polish.

“In using Soflex, a Kerfkore product, I find it has saved me in time and labor over traditional methods. It gives me a consistent result every time. It also has expanded our ability to be creative for the customer.”

ROGER SMITH | THIRD DAY CREATIONS 

Build What You Actually Designed

For too long, curves have been sacrificed to make projects easier or to reduce the budget. With Kerfkore, they don’t have to be.

Whether you’re designing a boutique hotel, a corporate lobby, or a luxury retail space, Kerfkore gives you the confidence to include curves without second-guessing the cost, quality, or execution.

Ready to stop compromising? Request a free sample kit and see just how easy curved fabrication can be.