En mass – CNC and hardwood plywood is the only
way to go.
I chose to use an MDF core, ¼-inch walnut plywood, since the core of the plywood has a nice consistent look, and complements the color of the walnut
veneer nicely. We designed and laid out the medals
so we were able to nest 200 medals per sheet of 4 x 8
We first sprayed on a top coat of lacquer to the entire
sheet, since that was much faster and easier than trying
to finish the medals individually. The first machining
step was to drill the 5mm hole that would accept the
ribbon. Then, using a V-bit, we machined in the “>5K”
logo and the ring around the outside. Finally, we cut the
perimeter of each medal using a 3/8-inch downcutting
bit, leaving just a small amount of onionskin, to prevent
the medals from moving around.
After two sheets of plywood, we had 400 wooden
medals! We lightly sanded the perimeter of each
If you trim laminate, you need the NEW
Trims within 1⁄ 16"
Flush & Eases Corner
ONE Tool – ONE Bit
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Patchin was able to nest 200 medals per sheet of 4 x 8