Picture of Laser Cut Whistle
In this tutorial, I will be showing you how to make a working whistle such as the one pictured above.

The materials you will need include:

- Access to a laser cutter (I will be using a CO2 laser)
- 0.115" plywood sheet
- Adhesive (I will be using carpenter's glue, although super glue may work)
- Access to a modeling software such as AutoCAD, Inventor, or any other .DXF compatible sketching software (Optional)
Remove these adsRemove these ads by Signing Up

Step 1: Sketching the Parts

Picture of Sketching the Parts
You can download the .DXF (2000 edition) drawing file directly from this page, or you can sketch something similar in a CAD program yourself.

If you do draw your own version, keep in mind that the wood will be 0.115" thick, so you will need to make the sockets 0.115" thick to make sure that the pieces fit together nicely.

NOTE: You can engrave a design on the sides or top of the sketch by placing the graphic on the face of the sketch in a drawing program. If you do this, place the graphic on each side piece so that when building the whistle, the graphic always points outwards.

Step 2: Cutting the Pieces

Picture of Cutting the Pieces
The pieces you will be cutting will need to be cut using the power your laser requires to completely cut through wood 0.115" thick. For the mouthpiece, you may have to experiment with several different cutting speeds to get the correct dimensions for a whistle sound to be heard when you blow into it. The space created by the mouthpieces worked for me at around 1/16" (0.0625") to 1/32" (0.03125").

After cutting the pieces in the laser, you will need to sand down the top piece so that a slanted edge is created at the notch in the front.
Kiteman1 year ago

Oh, I'd love to actually *hear* this!

How did you decide on the size and placing of the finger-holes?

Yes, I second Kiteman, we must hear this!

this is actually not a whistle but an ocarina.

True, but that doesn't stop it being cool!