Sample Club: Laser Cut Wood and Foam Halloween Wall Hanging

Files: Right click the file below and choose "Save target as." Open the file in CorelDraw 8 or later.

Start by opening the file boo_hanging.cdr. In Figure 1 to the right, you can see what the file will look like. Set up the images so they fit on the piece of wood you are working with, and print them to the laser in combined mode.

The dark area of the image will be engraved so that you can inlay the foam into the wood. For better results, mask the wood before engraving it.

We ran this file on a 75 watt Helix with the settings:
Raster: 75% speed, 100% power
Vector: 10% speed, 100% power

Next, open the file boo_foam.cdr. You will be cutting this file out of the sticky-back orange foam. For the best results, remove the backing before cutting the foam, sticking the sheet to your vector grid.

On the 75 watt, we ran this file at:
Vector: 100% speed, 25% power

After the shapes are cut out, place them in the engraved areas of your wood pumpkin and letters.

Next, open the file boo_shapes.cdr. You will be cutting this file out of the sticky-back black foam. For the best results, remove the backing before cutting the foam, sticking the sheet to your vector grid.

On the 75 watt, we ran this file at:
Vector: 100% speed, 25% power

After the shapes are cut out, place them on to the orange foam cut letters wherever you like.

Finally, attach the pieces together. In each of the letters and pumpkin, you will see a series of holes that were cut out. We are going to use the copper wire (or any picture hanging wire) to attach everything together. Start by cutting six 6.5" strips of wire and curling them around a pencil, as show to the right. Push each end of the wire through the holes and secure it by wrapping the ends together.

We also cut a hole through the top of the pumpkin stem that has been covered by foam. You can use this hole to hang your new halloween decoration!