Spooky LED Halloween Decoration - xTool Projects
Add an element of fun to your next decoration by designing your own Halloween Hanger using elements from the XCS shapes library! Once you're ready to assemble, it's easy to integrate an LED light string to really give your creation some life!

This design was cut on the P2, but could easily be adapted for use on the D1, D1 pro, or M1 series lasers!
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Step 1: Create your Front Decoration and Backer
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In XCS, you will start by creating a design using the elements available in the XCS shapes library.

 

First, insert a circle. I set the size of my circle to 295mm. This allowed me to place both the decoration and backer on 1 piece of 12"x24" wood. 

Second, I copied my first circle and resized it to 265mm and centered it. Then I made 2 - 8mm circles and spaced those within the boarder space. Align these two circles to ensure they are aligned on the horizontal axis.

Select the large circle and both 8mm circles, copy and paste to create the backer. Group these new shapes and move them to the side. If adding LED lights, remember to add a small circle to be cut in the lower bottom of your design to allow the lights to pass through.

Third, select the original circle and smaller inner circle, use the combine tool to select. Then select the large circle and the 2 small circles, combine and subtract.

 

Step 2: Design your Decoration
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Using elements from the shapes library, you can design your own unique design!

 

For my design, I began by inserting one of the spooky houses. I then resized it to fill the space and positioned it towards the bottom of the inner circle. To create one fully connected space, I also inserted a semi circle shape into the design. To adjust its dimensions, I had to click the lock between the width and height to adjust the shape to fit where I wanted it. Once the new shapes were in place, I selected each new element and the circle shape and combined using unite under the combine tool.

Next, I used the vector drawing tool to add clouds. The shapes can be whatever you would like. I chose to have one cloud start from either edge of the circle and move towards the middle. Once the rough shape of the cloud was created and closed, I double clicked each new shape, then double clicked the handles for each of the nodes/points I created. This revealed the curve tool and allowed me to adjust the final shape of each cloud. Then I selected both cloud and the circle to combine using unite.

The last shape I chose to add was a witch flying on her broomstick. I intentionally positioned the witch to overlap part of the edge of the design and the cloud to ensure she was well attached when cut out. Select the witch and circle elements and combine using unite.

If you want to add text, I would recommend using a stencil font if you want it to be simply cut out. Using a stencil font will ensure all parts of your letter remain clear and legible in your design. If you wanted to use a different font, you could experiment with different ways to connect it or cut it out separately and attach it to your design later.

You can watch my process in real time here on youtube!

Step 3: Cut out your design
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Setting 1
Process Method
Laser Cut
Process Material
3mm Basswood Plywood
Power(%) or Cut Pressure(g)
65
Pass
1
Speed(mm/s)
14
Other Parameters
Using the 1/4'' project board from Home Depot, I have found that there can be a number of voids in the material, as well as occasionally inconsistent pockets of glue. I have slowed my speed to better cut out. My air assist is at 100%. Use the settings that make sense for your material and machine.

Using the camera's of the P2, ensure your design is placed on your work plane and is within the working margins of your material. Once you are set, cut it out!

Step 4: Painting Your Pieces
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Painting your design can be as simple or as intricate as you would like! I chose to use a simple 2 tone paint job to create more contrast for my LED lights. 

I used Rustoleum 2x  Black Flat spray paint for the front decoration piece and Rustoleum 2x White Flat Spray for the backer. 

I applied 2 coats of paint to each piece and allowed them to dry.

Step 5: Attaching your LED light String
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I used a number of small circle cut outs I had available from other projects to create spacers for my LEDs. You can do the same, or use the small circles included in the design.

Using my E6000 quick set glue, I placed my spacers on the back of my decoration piece. I began by placing the spacers opposite each other. For example, on a clock, 12 & 6, 3 & 9, etc. You do not need to be too precise. I used 8 spacers in my final design. You can use more or less to support your piece.

Once the supports are dried, you can begin winding the LED light strip around the supports. I did this by looping the wire around each support and securing the path of the wire between supports with masking tape. Once all of the available light string was placed, I when around the line and added a small amount of glue to the wire secured by the tape to glue it into place. You can do the same. In the future, I may use hot glue for this application to speed up the curing of the glue, rather than the e6000 quick set.

Once all of your glue is dried/cured and your lights are placed, you can add the backer to the front decoration. I did this by applying a small amount of glue to each of the spacers, then aligning the hanging holes of each piece.

Design Files
Halloween Sign Demo- lighted.xcs
halloween
decoration
wall sign
LED
lighted
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