This was an enterprise project to raise funds for a project my students wanted to make.

Learning Objective
By making an engine turned coaster KS4 GCSE students will learn and apply knowledge in a practical situation. This knowledge covers use of an engine turning tool and CAD / CAM. This project was used as part of a enterprise activity where students made various products. By using this project in their enterprise activity students gain entrepreneurial skills and begin to see the link between time to make / materials cost Vs sale price.

Step 1: Engine Turning Tool

These can be bought but my students make their own
Put the tool into drill chuck

Step 2: Prepare the Guide

Create a guide that has lines spaced at 20mm apart, arranged in the pattern shown
Draw the lines of a flat piece of wood
Clamp to drill plate

Step 3: Engine Turning

Align the aluminium so the turning tool is in the top left corner
Move the aluminium as per the photos

Step 4: Vinyl

You have a few options here......depending on what equipment you have access to.
I cover the whole surface with the vinyl.......laser cut it.......peel off unwanted sections (best bit :)
Or use a plotter, then stick on your design
Or cut out with scissors or knife then stick on
Or buy some adhesive shapes, letters, or whatever and stick em on

Step 5: Varnish

Use Polyurethane varnish......it must be a water based varnish or the vinyl will peel
Put an even and very thin layer of varnish on...it only takes 10-20 mins to dry
Repeat until you have four coats
The varnish protects the aluminium from scratches and stops the vinyl from peeling off

Step 6: Enjoy :)

You can get vinyl in a massive range of colours including carbon fibre! Ebay is a good place to get supplies from
Now go and make awesome coaster / name plates