Laser Cut Door Mat





Introduction: Laser Cut Door Mat

Rugs Challenge

Runner Up in the
Rugs Challenge

In this instructable I will be showing you how to make a door mat out of wood using a laser cutter. I heard about the rug challenge and I thought to myself, what would make a unique "engineer' type door mat and this idea was just perfect for that. Its as simple as it can get. Piece of wood cut into a pattern to act as a door mat.

If you like this instructable, please vote for me. As always, it would encourage me to bring great new stuff.

Update Log 1.0 : I remade the door mat on 1/4 piece of plywood and it turned out great.

Step 1: Parts List

For this project I went cheap. No buying, just dumpster diving. Although I found many rough chipboard to work with, I settled with a 1/2 inch plywood sheet. Although what I learned was this was a bad choice but more on that later.

Step 2: CADing

I love to CAD everything now. I dont like corel draw much so I just used solid works to mock up my design. I started with a honey comb design but shifted to a rectangular pattern for ease of making and functionality.

Based on the dimensions of the plywood, I drew up a regular pattern and then exported a .dxf file. I did final corrections and printing in corel draw.

Attached are the files. You can use them but I encourage you to try to make up your own pattern.

Step 3: Laser Cutting Setup

I used an epilog laser cutter to make the door mat. I used corel draw to make sure all the cuts are hairline. I set the laser power setting based on the power chart. You can find the chart for the laser cutter you use online but here is the link for the chart I used.

Step 4: Laser Cutting Lessons

In all honesty, I messed up this project. Despite many attempts, I was not able to get the desired results. The problem with laser cutting 1/2 inch parts are that the laser only goes half way through. I cut the piece more that 5 times but it still did not cut through and through. At that point the wood was so charred and brittle that it just did not look good.

I was able to separate the pieces by force but it cause a lot of cracking and splitting in the plywood. It might look okay in the picture but it was not up to the mark so I just threw it away. I did not have the time or the patience to try to find a 1/4 inch plywood piece.

Hence I recommend you use 1/4 inch plywood. I might try it if I find some piece in the trash.

Step 5: Concluding Remarks

This project was a clear reminder that things dont always go as planned. I made mistakes and I learned from them. I hope you were able to learn from my mistakes so that you can make a good looking door mat. I am sure if I try one more time, i would be able to get it just right.

Thanks for viewing my instructable and once again, if you think it was helpful, do vote for me.

Step 6: Update Log 1.0

I remade the door mat using 1/4 inch plywood and it turned out perfect.



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    Great tutorial! Thank you!

    You might want to change your compuer password now...

    Haha thanks. And that is a computer in thinkbox. Not my personnel pc.

    Love the idea, I should be able to do this
    over at my local TechShop on our 40 watt Helix's. And I'd love raid that
    dumpster, I am always looking to squeeze every last sq. inch out of my
    cutting sheets.


    what style of laser is that chart for?

    its for an epilog legend 36ext

    This is an awesome idea.