Materials other than MDF

[RandyT]

I'm surprised nobody mentioned MDO plywood.  I have to order it from my local Home Depot, but I never have problems getting it.  Kinda pricey but really smooth and durable.

Heh.  Someone didn't read the whole thread....

[javeryh]

I don't understand the MDF hate.  I built my last cab out of it with zero issues whatsoever.  Just treat all of the surfaces (seal them) and it's simple to work with although the dust sucks.

[Ond]

Here is an example of two materials being used because they best suit the intended purpose.  In this case high grade marine ply and very thick MDF:

The marine ply piece is serving as a brace.  The thin curved piece needs to be strong and accept screws along its edge.  No problem with marine ply.  MDF would not have been as good a choice.

The MDF piece has a smooth curved edge which will later be finished to a very high gloss, painted finish. I could have used plywood for this, but from experience the exposed laminated edge when routed is harder to get a good finish on.  Again from experience the laminated edge over time can subtly change with changes in temperature, expansion, contraction, and so on leaving a slight distortion in the high gloss finish i.e. a visible ripple.  The MDF will have no such issue, ever.

Used properly, MDF has properties that make it superior to other materials in certain circumstances.

[jaywv1981]

I've been using melamine for the sides and PVC boards for the framing and have been super satisfied with the look.  The PVC boards come in white and can easily be spray painted any color.  I typically paint them black.