I made it at TechShop.

This playing card box was made from a floor joist salvaged from a 150 year old house that was in the process of being renovated. While working on this project, another TechShop member identified this piece as Spruce, and from the small amount of discoloration caused by Spalting, it was most likely cut from a tree that was dead for some time.

That means this project may actually be the second time this piece of wood was reclaimed!

Tools (available at TechShop):

Planer (optional)
ShopBot with 1/4" spiral bit
VCarve software
CAD software (Autodesk Inventor)
Table router with 3/4" round over bit
Laser etcher

Step 1: CAD Design

Using 3D solid model CAD software (Autodesk Inventor available at TechShop), a design was created. The reference dimensions were the length, width and height of a standard deck of playing cards, as well as the overall dimensions of the piece of lumber (this sets the size of the work piece).

Prior to creating the CAD design, the lumber was run through the planer (sorry no photos) just enough to remove the rough sawn sides. Afterwards, the thickness was measured, and fed into the CAD design.

The final design was read into the VCarve software to program the cutter paths and output the tool path file for the next step.

<p>You have been busy lately! Another great project! It's just so professional! I love it :D</p>
<p>Thanks. I got the idea when we were in the craft store and saw really cheaply made card holders made from super thin pieces of wood, that were basically just empty boxes with a divider in the center. The idea is that you could paint or stain it yourself. At first I thought about just adding the laser etching, but then realized I could make something much nicer.</p>
<p>Very impressive. Time for me to build that CNC router and Laser engraver!!</p>
<p>great job!</p>
<p>This is really nice, and aside from the laser etching wouldn't be too hard to make using traditional tools. I love that Johnson's paste wax, it's great stuff!</p>
<p>For the first coat of paste wax, I actually melted some in a coffee cup in the microwave and painted it on with a brush, and it soaked right in.</p>
<p>Good tip, I'll have to try that if I'm ever using it on especially dry wood. Thanks!</p>

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