How We Manufacture Custom Plywood Volumes
Process, Materials, and DIY Considerations
What Are Plywood Climbing Volumes?
Plywood volumes are three-dimensional climbing structures manufactured from high-quality birch plywood, typically assembled from multiple CNC-cut panels.
They are designed to:
- Create large features and angles on climbing walls
- Support bolt-on holds and screw-on elements
- Add route complexity without excessive weight
Most commercial gyms use plywood volumes for indoor applications, competitions, and frequent route resets.
How We Manufacture Custom Plywood Volumes
At a professional manufacturing level, producing plywood volumes is a controlled, repeatable process, not simple woodworking.
1. Design & File Preparation
The process starts with customer-provided designs, usually in:
- 3D formats: STEP, STL, OBJ
- CAD drawings: DXF, DWG
Designs define:
- Volume geometry
- Panel angles
- Fixing points
- Assembly structure
Before production, our engineering team reviews each design to ensure structural strength, manufacturability, and safety.
2. Engineering Review & Optimization
Not every design that looks good on screen works well in real-world climbing use.
We evaluate:
- Plywood thickness selection
- Load distribution and stress points
- Edge alignment and panel joints
- Fixing methods to the climbing wall
When needed, we provide feedback to optimize durability and reduce unnecessary cost.
3. CNC Machining of Plywood Panels
All plywood panels are cut using high-precision CNC machines, ensuring:
- Accurate geometry
- Clean edges
- Consistent dimensions across batches
CNC machining allows us to reproduce the exact same volume repeatedly, which is essential for commercial gyms and brand partners.
4. Assembly & Finishing
After machining:
- Panels are assembled into the final volume structure
- Joints are reinforced where required
- Edges are sanded and hand-finished
Volumes can be supplied:
- Raw plywood
- Painted
- With textured or coated surfaces
5. Quality Control
Each volume undergoes inspection for:
- Dimensional accuracy
- Structural integrity
- Edge quality and safety
Only approved products proceed to packaging and shipment. Testing standards and inspection criteria can be provided upon request for commercial projects.
Manufacturing Process Overview
In short, the professional process looks like this:
- 1 Design submission (3D / CAD)
- 2 Engineering review
- 3 CNC machining
- 4 Assembly & finishing
- 5 Quality inspection
- 6 Packaging & delivery
This structured workflow ensures consistency, safety, and scalability, especially for commercial environments.
Can I Make My Own Plywood Volumes?
Yes -- small DIY plywood volumes are possible, but there are important limitations.
DIY Plywood Volumes: What's Realistic
You can make basic volumes if you have:
- Quality plywood
- Accurate cutting tools
- Basic understanding of load and fixing points
DIY volumes are typically suitable for:
- Home walls
- Training boards
- Experimental shapes
Limitations of DIY Volumes
However, DIY production often struggles with:
- Inconsistent geometry
- Weak joints
- Poor edge finishing
- Limited repeatability
- Higher risk under commercial loads
For commercial climbing gyms, DIY volumes usually do not meet durability, safety, or consistency requirements.
Professional Manufacturing vs DIY: A Quick Comparison
| Aspect | DIY Volumes | Professionally Manufactured |
|---|---|---|
| Precision | Limited | High (CNC machined) |
| Repeatability | Low | Excellent |
| Structural Strength | Variable | Engineered & tested |
| Surface Quality | Inconsistent | Consistent & safe |
| Commercial Use | ❌ Not recommended | ✅ Designed for gyms |
When Professional Manufacturing Makes Sense
Professional plywood volume manufacturing is the right choice when you need:
- Commercial-grade durability
- Consistent quality across batches
- Accurate reproduction of designs
- OEM or brand-level production
This is why most gyms, brands, and route setting teams choose factory-produced plywood volumes for long-term use.
Final Thoughts
Plywood volumes may look simple, but professional-grade volumes require precision engineering, controlled manufacturing, and experience.
Whether you are:
- A climbing gym owner
- A route setter
- A climbing brand
Understanding the manufacturing process helps you make better decisions -- and safer routes.
Want to Produce Custom Plywood Volumes?
If you have 3D or CAD designs and are looking for reliable, scalable production, we support OEM manufacturing for international climbing brands and gyms.
👉 Contact us to discuss your designs and project requirementsWritten by: SCT Climbing Manufacturing Team
SCT is a professional manufacturer of climbing wall panels and plywood volumes, specializing in OEM production for international climbing gyms and brands.
