We will use bright orange powder coat to make a shiny square. The material will be mild steel which is quarter inch thick. This is one mighty heavy square that can be used for a variety of purposes. So far it has been used as a coaster, a paperweight, decorative art, and as a threatened weapon - unfortunately directed at myself.
I made this at TechShop Detroit (www.techshop.ws).
Step 1: Cut Metal Flat Bar Into Squares
We start with a 3" wide meta flat bar. Using the horizontal band saw, we secure and cut the bar into 3" x 3" squares. Put the bar into the band saw and tighten it enough that it can still move. Then measure such that the blade is exactly 3" from the edge of the bar. Use a blade speed of 165 (for mild steel) and a feed rate of 2.5 (between 2 and 3 for mild steel). Cut as many squares as you would like.