design considerations

material

Based on our tests, MDF seems to work best because it is uniform and flexible. Other types of manufactured panels also work but the irregularities of standard lumber will lead to complications. You can apply veneer to a curved panel to simulate hardwood.

size of panel

There isn't a size restriction, but larger panels will be harder to cut and clamp. Also, the larger the panel, the more help you will need for the gluing/clamping step.

thickness of panel and kerf dimensions

We used 3/4" (19mm) thick MDF so the completed curved panel was 1.5" (38mm) thick. You can use a thinner panel but you may have to change the kerf dimensions. The thickness of the material left at the bottom of the kerf remains critical and 1/32" (1mm) is a good guideline. Remember that the material that remains between the kerfs serve as the gluing surface and therefore cannot be undersized. You can use thinner table saw blades as well. It is best to experiment for your particular situation.