With this Instructable, I'll show you how I created a custom light switch cover. It's a nice way to personalize a child's bedroom or add something unique to your own.
I made it at TechShop.
Step 1: Measure
Using a set of digital calipers, I created a graphics file that has the same dimensions. You'll need 2 rectangles (the overall shape + the light switch hole) and 2 circles (for the screws).
If you want to skip that step, I've attached the Corel Draw file that I used. It already contains the guide marks and hole layouts.
Next, customize with your own graphics. Be creative and add whatever shapes, letters, or drawings that you'd like.
Step 2: Send It to the Laser Printer
I decided to use a piece of 1/4" plywood. I found some pieces in the scrap bin at TechShop so I decided to use those.
Once you're ready, send it to the laser printer. I'm using an Epilog 60w and these are the settings I used for both the raster and vector cuts.
Step 3: Clean Up the Edges
Using a disc sander, I cleaned up the edge to remove the burn marks from the laser. While I was at it, I put a small chamfer along the sides to remove the sharp corners.
And that's it! Optionally, add wood stain to match the design of your room.