Playing Card Butterfly Popout

Information

      Playing Card Butterfly Popout

Please LIKE and DOWNLOAD for contest votes to count! THANK YOU!

🃏 Playing Cards → 3D Butterfly Build (F2 Ultra UV)

Trying to think out the box - combining hobbies that I’ve had throughout the years - magic, poker, and now engraving… Had an idea to turn standard playing cards into dimensional butterfly pieces (Hello NYC Spring!) — concept was simple… execution, not so much 😅

Took several iterations to dial this in.

Setup:
• Machine: xTool F2 Ultra UV
                     - Center and frame your playing card
• Make sure to use your cut-plate!
• Material: Standard coated playing cards
• Settings: Default paper settings
                     - Tweak speed from 55 to 43 for a better cut (do not leave the laser machine - risk of fire!)
• Final: Must bend the butterfly inside out through one wing hole. You will tear (twist) a bit on the 'hinge pin', where it's hidden.

Process Overview:
1.	Designed important parts of layered butterfly cut pattern directly in xTool Studio (1.6.6)
2.	Multiple test passes to dial in clean cuts, and figure out fonts that would work
3.	Careful attention to hinge points — too thin = tear, too thick = won’t form cleanly
4.	Final step is manual forming to give the wings that raised 3D effect

Challenges:
• Popping out tiny intricate details for those areas that didn’t fall out themselves
• Getting clean cuts without fraying the edges
• Structural integrity at the center pivot point with needed special bend

Takeaway:
Default paper settings were actually a solid starting point — most of the work was in design and iteration, not the laser.

Honestly started this knowing what I wanted, just not how to get there — took a few failed attempts, but that’s where the learning happens.