Rounded corners can be made by routing to a template, sawing close to a layout line and sanding to shape, or working entirely with hand tools. The best method depends on the radius, how many identical corners you need and the tools available.
Router and Template
For repeated identical corners, make an accurate template and use a bearing-guided router bit appropriate for the operation. Remove most waste first rather than asking the router to remove a large corner in one pass.
Jigsaw or Bandsaw
For medium and large radii, mark the curve, saw slightly outside the line, then refine to the final shape with sanding, a rasp or a pattern-routing step. A bandsaw is useful in a stationary shop; a jigsaw is the portable alternative.
Hand-Tool Method
A rasp, file, spokeshave or sanding block can create rounded corners without power tools. Work to a clear layout line and check symmetry frequently.
Repeatability
If several parts must match, a template becomes more valuable than repeatedly drawing and shaping each corner independently.
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