Summary

This item replaces the hexagonal tiles in Settlers of Catan with tiles that interlock. It will produce the 19 hexagonal tiles that comprise the basic set, as well as a bunch of tokens to represent the ports.

Instructions

The current latest version of this file is "catan9." The attached files are:

catan9.cdr -- for use with CorelDraw X5
catan9.x3.cdr -- for use with CorelDraw X3
catan9.svg -- for Inkscape and everybody else

This CDR file contains three layers:

a "cutting" layer containing nothing but vectors for cutting
a "raster" layer for etching
a "NOTES" layer for instructions (don't print)

Thing thing requires two passes on the laser cutter: an etching pass, which takes about 45 minutes on an Epilog Helix, and a cutting phase, which takes around 15 minutes on an Epilog Helix.

Note that the "raster" layer contains some vectors. You need to either convert the entire raster layer to a bitmap (step 4 below), or else take other steps to ensure that the raster layer only etches, not cuts, your design.

Suggested build process:

Materials: I've had good success using wood and cardboard for this design, and moderate success (so far) with etched acrylic.
Load up the design, and scale all layers to fit your material (but don't change the aspect ratio).
Test cut one of the surplus "port" tokens on the left side of the design to get your etch/cut settings right. After step 4, you won't be able to do individual token test-etches anymore.
In CorelDraw, select the entire "rasters" layer and convert it to a single bitmap (invoke "Bitmaps -> Convert to Bitmap..."). By consolidating all the bitmaps into one master bitmap, your laser cutter will etch more efficiently. Also, since the entire rasters layer is now a bitmap, you can fine-tune your laser parameters to have the bitmap settings for etching, and the vector art settings for cutting.
Delete the NOTES layer so that you don't accidentally cut it.
FIRE THE LAZZZOR! On TechShop's 65W Epilog Helix, this design took just under an hour to etch and cut into acrylic.

EXTRA CREDIT IDEAS:

Consider turning off the "rasters" layer altogether, and instead printing some very nice color printouts that you then glue onto your laser-cut pieces.
Consider cutting the different game pieces out of different colors of acrylic.
If you have suggestions for improved etchable artwork for the tiles, please submit them to me and I'll incorporate them into the design!
Consider flattring me: http://flattr.com/thing/134363/Lasercut-tiles-for-Settlers-of-Catan (Definitely not required, I'm just curious if this flattr thing will catch on.)

Lasercut tiles for Settlers of Catan