How I Prototyped a Memorial File to Commemorate the End of the US Penny and How You Can Get Yours!
In late 2025, I was commissioned to create a commemorative Christmas ornament marking the end of the US penny era, with the 2025 penny being the last minted. I designed multiple versions, including wooden replicas of historic pennies, and prototyped the final design using a 40-watt diode laser. This article details the design process, laser engraving steps, assembly, and how you can obtain the files at a discount.
This project is available for purchase on my website:
🔗 https://engraveandcutfiles.com/
In late October 2025, I was contacted to create a commissioned file for a commemorative Christmas ornament marking the end of the era of the US penny. As many know, the 2025 penny is the last one ever made, making it a significant piece of American history.
Designing the Commemorative Ornament
I initially created a file for the ornament, featuring the front and back designs. Inspired, I decided to make my own versions as well. I developed a couple of different versions, including wooden replicas of three different types of pennies. These wooden pennies represent historic mint locations and the final penny, which is extremely rare and valuable.
The Wooden Penny Versions
- Philadelphia Mint Penny: Includes text such as “The third Philadelphia Mint opened 1901 Spring Garden Street”.
- Denver Mint Penny: Another historic mint representation.
- Final Penny: A recreation of the last penny ever made, which is extremely rare with only a dozen made for auction, expected to fetch millions.
All these designs are available as SVG files, along with the original image files used to create them, perfect for engraving and cutting out of wood.
Prototyping with a 40-Watt Diode Laser
I used a 40-watt Alien Cell diode laser to prototype the final design. Although I have a 60-watt module, the 40-watt is more common and suitable for this project.
Preparing the Laser Software
- I used the Alien Cell software to import the SVG file.
- Deleted previous prototypes and started fresh.
- Signed out to demonstrate that no account is needed to use the software.
- Imported the final prototype file by dragging it into the workspace.
Setting Up the Project
- Selected the material as basswood or plywood, approximately 3 mm thick.
- The software automatically adjusts the focus based on material thickness.
- Ungrouped the design elements to assign engraving and cutting paths.
- Set all black elements to engrave and red elements to cut.
Adjusting Laser Settings
- Engraving speed set to 550 mm/s with 95% power.
- Cutting speed adjusted to 13 mm/s with 100% power to avoid issues with glue pockets.
- The 40-watt laser is more powerful than advertised, capable of cutting 3 mm plywood efficiently.
Positioning and Live View
- Used the laser’s live view camera to position the design on the wood piece.
- Grouped and moved design elements to fit the material.
Engraving and Cutting Process
- Started the engraving job wirelessly.
- The laser automatically powered on, focused, and activated air assist and exhaust fans.
- The air compressor increased during cutting for a clean finish.
- Noise reduction was turned off in the video to capture the sound of fans and compressor.
Air Quality and Safety
- The air quality indicator remained stable during cutting.
- The double fan exhaust system effectively removed wood smoke and odors.
Assembly of the Commemorative Ornament
- The design consists of multiple wooden layers that fit together with tabs.
- The base layers are longer to display text clearly.
- Used super glue to assemble the layers, applying small amounts carefully to avoid excess.
- The rim piece fits over the assembled layers, leaving a gap at the bottom to read the text.
- The final step was gluing the recreated penny into the center.
Important Notes on Assembly
- The slots in the design are sized for 2.8 mm wood; adjustments were needed for 3.25 mm wood.
- Resizing the slots before cutting ensures a perfect fit.
- The super glue used does not stick dramatically to fingers, making handling easier.
Final Thoughts and How to Get Your Own Files
The final prototype turned out perfectly, showcasing clean cuts and beautiful engraving. I plan to create versions on painted wood for a more polished look.
The files for all versions, including the Denver Mint penny, Philadelphia Mint penny, and the final penny, are available in my online store. A coupon code is provided for a deep discount, allowing you to get these files for just pennies.
Thank you for joining me on this journey to commemorate the end of the US penny. I hope you enjoy creating your own memorial ornament as much as I enjoyed making mine.
Stay tuned for more projects and updates!