This report investigates the feasibility of using spindle motor power or cutting force measurements to determine the sharpness of router tools during operation. Machining tests were conducted on FPInnovations’ Shoda 3-Axis CNC router using new and worn standard straight flute tools cutting melamine coated particleboard. Spindle motor power was recorded during the machining operation and after a series of machining passes, cutting force measurements were taken on a test sample mounted to a 3-axis dynamometer. Testing revealed that although machining power increases with tool wear, the change in power is not large and tool geometry had a larger effect on power requirements than the changes in tool sharpness. Analysis of cutting force measurements showed that forces normal to the machined face varied linearly with tool sharpness and were much more sensitive to changes in tool condition. Again tool geometry can greatly affect the machining force so implementation of force measurement tool condition monitoring would require differing “end of life” criteria for different tool geometries.