Overview
A passion project with a friend to create custom poker chips for our weekly poker nights. The goal was to design and manufacture a complete chip set using CNC lathe operations, exploring different manufacturing approaches and materials.
Manufacturing Approach
After testing multiple manufacturing methods (waterjet, manual milling, laser engraving), we've settled on a streamlined two-operation CNC lathe process combined with laser customization:
Machining Demonstration
Watch the complete machining process that brings our poker chip design to life:
Operation 1: CAM-Programmed Roughing & Knurling
Starting from long bars of material, we use CAM software to program the initial operation:
- Create cylindrical chip body with precise diameter and thickness
- Add knurled pattern on edge for texture and visual appeal
- Create recessed center area for inlay or engraving
- Cut off finished chips from the long bar stock
Operation 2: Hand-Programmed Secondary Operation
The second operation is hand-programmed directly on the lathe for added details:
- Additional chamfering or edge finishing
- Fine-tuning any dimensional features
- Creating specific groove patterns or designs
- Customization based on denomination or material
Laser Engraving
Final customization and personalization through laser engraving:
- Add denomination values and suit symbols
- Apply custom designs or logos
- High-precision marking without material damage
Multi-Metal Vision
The long-term goal is to create chips from different metals, with each denomination having a unique material and appearance. Starting with aluminum prototypes, we plan to expand to brass, steel, and copper to provide visual distinction and different tactile feedback at the table.
Key Skills Demonstrated
Manufacturing & Design
- CAM programming and optimization for batch production
- Hand programming CNC lathes for custom operations
- Knurling and specialized surface texturing
- Design for manufacturability with multiple materials
- Laser engraving customization and marking