My friend wanted to make an Ezio Costume for Halloween and needed this crucial piece made.
The buckle is ornate and pretty hard to make with drawing and carving on a piece of wood so he sketched it up on Illustrator.
I cut a piece of clear Acrylic to fit on the laser and had it done in an evening.
Laser Cutter / Etcher
Silver acrylic paint
1/4" Plywood backing
Step 1: Graphic Design Setup
Ezio's buckle was drawn up by Ryan Patron in Adobe Illustrator.
Two layers were used - one for the etching or rastering, This will give us the details of the design slightly below the surface. The second is an outline or vector which will be where the actual cutting happens.
I used an Epilog Helix 45 watt laser.
The Illustrator file is attached. Thanks to Ryan for sharing his file.
Step 2: Laser Etching - Test Pass
We ran a test pass to see the depth of the etching - we wanted the design to stand out!
Since it is a pretty big piece, the laser etching takes a while - the test passes let us practice on smaller scraps so we don't waste material.
Step 3: Laser Etching the Buckle
Testing is done and we liked the way it looked.
Time to run the final piece.
Step 4: Laser Cutting
Once the Raster is finished we move on to the Vector cut.
Step 5: Final Assembly
With the buckle cut out, all that was left to do was paint it silver and add the backing plate and belt strap. I really love how the acrylic got a good texture from the laser, it shows the details off really well.
Step 6: I Made It at Tech Shop!
This instructable was made at the Tech Shop in Menlo Park.