I’ve rearranged my 1500 square foot shop four times in three years, and I finally stopped breaking my shins on the CNC table.
Why Layout Actually Matters
Most people set up their shop based on where the electrical outlets are. I did that too. Then I spent six months walking back and forth between the laser and the computer like an idiot because I didn’t think about workflow.
Good layout isn’t about making your shop look clean for Instagram. It’s about cutting down the number of times you have to carry a 4×8 sheet of plywood across the room or hunt for a tape measure you just had in your hand.
You don’t need a huge space. You need zones that make sense and tools you can actually reach. I fit two laser engravers, a CNC router, a full woodworking setup, and a metal cutting area into 1500 square feet. It works because I stopped trying to cram everything against the walls.
My Zone Breakdown
Here’s how I split the space.
1. Design and computer zone (100 sq ft corner)
I run three monitors because one screen is never enough when you’re toggling between Lightburn, Fusion 360, and a parts supplier website. This is near the laser area so I can tweak a file and run it without crossing the whole shop. The desk is an old door on two filing cabinets. I keep a small parts bin rack next to the monitors for screws, Allen keys, and lens cleaning supplies.
2. Laser zone (400 sq ft)
Both lasers are here. The CO2 is closer to the wall because it needs the exhaust vent. The fiber sits on a welding table so I can swap between cutting sheet metal and engraving without moving materials around. I keep a rolling cart between them with spare lenses, nozzles, air assist fittings, and a notebook where I write down settings that actually worked. The cart moves when I need floor space and stays put when I’m running production.
3. Wood zone (500 sq ft)
Table saw, miter saw, router table, and hand tool wall. This is the messiest area and it’s intentionally far from the lasers because sawdust and laser optics don’t mix. I have a small assembly table here that doubles as an outfeed table when I’m ripping plywood. Scrap wood goes into a vertical rack I built from 2x4s. It keeps offcuts organized and I can see what I have without digging through a pile.
4. Metal zone (300 sq ft)
Welding table, angle grinder, drill press, and metal stock rack. This is near the overhead door so I can load steel without dragging it through the wood area. I keep a fire extinguisher on the wall here and a welding curtain that rolls down when I’m running the MIG. The fiber laser is close enough that I can mark parts after cutting or welding.
5. Staging and shipping area (200 sq ft)
This is near the door. I pack orders here and keep shipping supplies on wire shelving. Finished products sit here until they go out. It’s also where I put tools I’m about to return or materials I just picked up. Keeps the rest of the shop from turning into a dumping ground.
Dust Collection That Actually Works
I don’t have a fancy cyclone system. I have a 2HP shop vac on a rolling base and a 1.5HP dust collector with a trash can separator.
The dust collector runs to the table saw, miter saw, and router table through 4 inch hose. I added blast gates so I can close off the tools I’m not using. That keeps suction strong and stops me from pulling dust out of a machine that’s sitting idle.
The shop vac handles everything else. Random sanding, drill press cleanup, and clearing out the CNC. I keep it on a dolly so I can move it around. The hose is 10 feet long and that reaches most of the shop from a central spot.
I sweep the floor every day. Not because I’m tidy. Because wood dust on the floor gets tracked into the laser area and then I’m cleaning mirrors every other day instead of once a week.
Triple Monitor Setup
I mounted three 24 inch monitors on a single arm that clamps to the desk. The center monitor is for whatever software I’m using. Left monitor is for reference images, cut files, or the Monport camera feed when I’m running the CO2. Right monitor is email, order tracking, and whatever else I need to check without closing my design file.
This setup cost me about 300 bucks total. Used monitors are cheap. The arm was 80 dollars on Amazon. I added a small HDMI switch so I can toggle between my desktop and my laptop without unplugging cables.
I can work on a design, check material specs, and adjust laser settings without switching windows or walking to the machine. Saves me maybe 20 minutes a day. Over a month that’s 10 hours I’m not wasting on stupid task switching.
Common Layout Mistakes
- Putting your most used tools in the back corner. I did this with my miter saw and walked an extra mile per week.
- No space around machines. You need room to load materials and pull finished parts. I left 3 feet on the sides of my CNC and it’s still tight when I’m working with full sheets.
- Blocking your own path. I used to have my scrap bin between the table saw and the door. Every time I carried plywood in I had to move the bin first.
- Ignoring power. Extension cords across the floor are a tripping hazard and they tank voltage on big machines. I added two 20 amp circuits and it solved half my problems.
- Keeping everything. I threw out or sold a bunch of tools I never use. That freed up 150 square feet and I don’t miss any of it.
What I’d Change
If I were starting over I’d put the design area in the middle of the shop instead of the corner. I spend half my time there and the other half running between machines. A central desk would cut my walking in half.
I’d also add more overhead lighting. I have six 4 foot LED shop lights and I still use a headlamp when I’m adjusting the CNC or cleaning laser optics. You can’t have too much light.
And I’d build the assembly table on locking casters. I move it around more than I thought I would and dragging it across the floor scratched up the epoxy coating I paid too much for.
Your Next Step
Draw your space on graph paper. Mark your outlets, doors, and windows. Cut out little squares for each tool and move them around until the layout makes sense. Don’t guess. Measure your machines and add the space you need to work around them.
I did this on a Saturday morning and it saved me from another bad rearrangement. You’ll see problems on paper that you’d miss if you just started shoving tables around.
And if you’re setting up your first shop, start small. Get your main tools in place and add the rest as you figure out what you actually need. I bought a bunch of stuff I thought I’d use and half of it sat untouched for a year.
If you want help with laser placement or dust collection routing for your Monport setup, head over to MonportSupport.com. I’ve got diagrams and photos of my actual shop layout that might give you ideas.
Use code BMS13 when you order your next Monport machine or accessories and you’ll save a few bucks while helping me keep this site running.