Sabacc Coasters - Design Tech Project

My project was to make a set of coasters inspired by the fictional card game Sabacc from Star Wars. I really like the way the HDPE sheet creates some interest by having the alternate color appear as an island.
I made my Coaster out of Colorcore® High Density PolyEthylene carved on the CNC router. The holder was made using the laser cutter. 
To create my design, I used Adobe Illustrator and a few reference images to create the designs for the coasters and the holder. 
   
Once I had designed everything, I began cutting parts on the CNC router. 
The router leaves small feathers of plastic behind after cutting so the reduce this, I used a X-Acto knife, and a pottery cutting tool to remove the material that was not removed correctly. 
The holder was cut from 1/4 inch acrylic sheets. It was fairly simple onec the fit of the joints had been dialed in to the final sizes.

One of the most challenging parts of the project was the holder. My idea required several precisely tuned dimensions. The mortises in the base and the slots for the coasters. The laser cutter causes a small amount of material to vaporize when cutting resulting in some dimensions to become slightly off. I created five different parts to test what sizes to enter in illustrator in order for everything to fit well.

I would change to coaster holder design, if I were to do this again because it ended up feeling flimsy and poorly made due to the flex in the uprights. I would also consider changing the way I cut or process the coasters to reduce the feathering problem

Now that they are done, the coasters are going to sit on my desk. For when I want to have something to have a glass of water while I'm studying to protect the wood.




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