Instructables

Laser Cut Craft Foam Throwing Stars For Your Kids (or yourself)

Picture of Laser Cut Craft Foam Throwing Stars For Your Kids (or yourself)
Quick, and awesome project to make safe throwing stars for children. They don't fly terribly well, but young kids wont notice.

You will want to get the thicker 1/4 inch craft foam as the thin 1/8th stuff is just too flimsy.
 
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Step 1: Have Kids.

No pictures for this step, if you don't know how this part is done, Instructables might not be the place to find out, but the internet has plenty of other sites that should help.

If you don't want to have kids (its a long wait) you could adopt, or find somebody to love that already has kids. I did the latter, and now I have two awesome dudes to make throwing stars for.

You could, theoretically, make them for yourself I suppose too.

Step 2: Find your inspiration.

Picture of find your inspiration.
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Google throwing stars, or some similar and find stars that you like. Save the images so you can bring them into illustrator, jpeg should work just fine.

Step 3: Create vector images of the throwing stars.

Picture of Create vector images of the throwing stars.
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I used Adobe Illustrator, you can use this, or Corel Draw, even Autocad if you want. In Illustrator you may be able to use live trace, but I chose the pen tool. Trace the starts and resize accordingly, mine are about 2.5 inches square.

Make sure your line weights are small enough to be read as a cut line on the laser. If you don't know how to use a laser cutter, or don't know where to find one, try TechShop, we have you sorted.

Step 4: Take your file to the lasers and cut it up.

Picture of Take your file to the lasers and cut it up.
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Save your vector file and head to Techshop, or some other place with a laser cutter and go to town. Using the proper settings I think each 8.5 x 11 sheet of craft foam took about 1 minute to make into 8 throwing stars and 2 batarangs.

Make sure you know what youre doing so you don't make a mess of your foam or the machine.

Also helps to clean the lasered edges with alcohol or so to get the burn smell off.
tr6canuck5 months ago

Is this foam safe to use on a laser? At TechShop? Did you get the DC's approval? I am looking for foam to make inserts for laser cut boxes.

pippi462 years ago
Hi very nice job, compliments.
I would like to put some of your art on my website,
Would you contact me at lori.venturi@gmail.com
Thanks
Loredana
these are awesome! I have a feeling these would keep some adults I know very entertained as well! will you post your eps files?