Brown BDW-made Keychain

• BDW Monitor in Training project for Fall 2019
• Keychain project that utilizes laser cutter, 3D printer, woodworking tools, metalworking (optional)

Supplies

• Chipboard (side of toolboxes from Intro wood workshop)
• Pen

Tools used

• 3D Printer
• Laser Cutter
• Drill Press
• Sandpaper

Step 1: Laser Cut Keychain Body

• using the attached Adobe Illustrator file, follow the standard laser cutting procedures to etch the main design onto a piece of chipboard (the same material used for the sides of the toolbox from the intro wood workshop)
• Note: It is also possible to use a bandsaw to cut the outline of the body in case you would rather have an unburned side, this is an aesthetic choice
• TODO: figure out what settings were used

Step 2: Sand Wood

• using sandpaper, lightly sand the top and side surfaces of the wood to remove burned material from the wood

Step 3: 3D Print Carabiner

• Using included .stl file, 3D print the carabiner
• TODO: figure out the scale

Step 4: Drill Hole in Body

- Using a 1/4" bit and the 620 rpm drill press, slowly drill a hole in the corner of the keychain body

- Note: some splintering on the back of the body is likely

Step 5: Optional Step: Create Metal Cross Piece

• Using a small piece of sheet aluminum (the same kind used in the intro metal workshop) and hand shears, cut out a metal piece in the same shape as the central cross on the Brown shield
• Note: be careful of sharp edges

Step 6: Optional: Hot Glue Metal Cross to Keychain Body

• Using a hot glue gun, glue the metal piece to the central cross piece of the Brown shield
• Scrape off excess hot glue

Step 7: Optional: Color in Raster Engraves

• Using a ballpoint pen, color in the raster grave indentations