Overlay cutting (Making new ones)

[Pioneer4x4]

I was thinking about this again and was wondering about one of those "cricut" deals or something like that. Are there any that could cut a overlay for the 12 button controllers? (or the star trek type) I really want to make some as professional as I can, and I KNOW I cannot cut them by hand to my satisfaction.

[awhite2600]

I know that the old cricut machines did not allow you to cutout arbitrary shapes. You could only cut out shapes from their overpriced font cartridges. Someone hacked the USB port and released software that would allow you to cut out from TrueType fonts, Illustrator, etc.

 

I don't know if there is any software to allow newer models to be computer controlled. I kind of doubt it as Cricut makes their money from the font cartridges.

[Pioneer4x4]

I know that the old cricut machines did not allow you to cutout arbitrary shapes. You could only cut out shapes from their overpriced font cartridges. Someone hacked the USB port and released software that would allow you to cut out from TrueType fonts, Illustrator, etc.

 

I don't know if there is any software to allow newer models to be computer controlled. I kind of doubt it as Cricut makes their money from the font cartridges.

They have some version that you can design your own via a web page, and as long as you are signed in you can use it.

That basically sums up what I know. I am more interested in

Assume that I can create my own template, either manually, or overlaying curves and rectangles basic shapes.

Do they work at all? Will a Cricut (or other device) actually cut something nicely enough to make a usable overlay? I would get them printed at Office Max/Depot

[Crazy Climber]

Doesn't Ax have access to a die cutter? That should do the trick.

[Pioneer4x4]

I dunno, I'd like to do it myself, and any excuse to buy a new tool...

[snstay]

Im looking for a nice set of overlay as well.

Ill start looking for a way to cut them.

[Pioneer4x4]

looks like the basic shapes included on the $99 cricut will work to assemble a decent overlay.

[snstay]

looks like the basic shapes included on the $99 cricut will work to assemble a decent overlay.

would it do the fancy ones too like for space shuttle, or star trek i wonder.

[Pioneer4x4]

looks like the basic shapes included on the $99 cricut will work to assemble a decent overlay.

would it do the fancy ones too like for space shuttle, or star trek i wonder.

I think with combining you can get pretty close. Does anyone have dimensions on all of them? (Maximum outer dimension)

[Pioneer4x4]

I looked at this a bit more and I think with the "Basic Shapes" and using the Cricut Design Studio software that you can use (You must have the cartridge with the shape you want to use in the program) you can "weld" shapes together and make fairly complicated shapes quickly. There are better cutters for this type of thing (design your own shapes) but not verry common uses/cheap.

You can use squares, rectangles, triangles, circles. And you can resize/skew them all, and also add rounded corners. I bet you can do a decent job of even the star trek type! It supposedly can cut vinyl and cardstock. I think I am on to something. Now to convince my wife...

[Pioneer4x4]

Well, I ordered one from eBay, should be in soon. I worked up basic designs for the 3 different 12 button controllers. Once it comes, I'll see how well it cuts and what all I can cut on. Hopefully something durable enough that handling doesn't wear them out. Cardstock might be OK if laser printed.

 

Also I need to ensure I can print on it, and cut after, keeping everything aligned.

What overlay would be the most needed? I assume the Video Touch Pad is most common since everyone has Star Raiders, and the ones for Basic Programming are the rarest, and the Kids Controller is in the middle?

Edited June 27, 2012 by Pioneer4x4

[Pioneer4x4]

Well i got the cricut and was impressed by the hardware until I tried it out. I was impressed with everything except the actual cuts at first. It would either score or tear the paper, not cut it. I tried several papers, and construction paper.

Then for kicks I tried cutting some high quality 4x6 photo sheets, and they cut absolutely perfect!

So I wend on to perfect my designs for the overlays, and I was able to design and cut the following.

• The "Video Touchpad" for Star Raiders with locating tabs
  
• The "Atari Keypad" for basic programming with all 12 holes and locating tabs.
  
• One for the standard 2600 joystick with hole that catches on the center rubber and hole for the red button.
  

I did not finish the Kids Controller one since it would not fit on 4x6 paper. I need to grab my stack of photo paper and test that.

I also want to make one for the Track and Field Controller for kicks.

 

Now I need to try printing first then cutting. I'm sure alignment will be fun. Ideally I can laser print them to make it more durable than inkjet, or maybe I'll try clear spray over inkjet.

When I get a chance, I'll scan and photo how well they came out. The photo paper I used feels very much like the original material of the Basic Programming and Star Raiders overlays.

[+Nathan Strum]

I'd be interested in knowing if it would work for overlays I made for the SynthCart. Cutting them out by hand was a pain.

[Pioneer4x4]

Tell you what, I'll use those as my first try on the Atari Keypad. What did you use as the diameter on the holes (And how did you cut them, that had to be a PAIN)? I think I worked it out to cut them .375" diameter, and .6" apart.

Maybe I'll try this as well

http://www.atariage.com/overlay_page.html?SoftwareLabelID=2004

Obviously my main reason is for the R.O.B. controlling cart I made, but I haven't laid out a design for it yet.

[Pioneer4x4]

Also, can you give me the actual dimensions/locations on your pdf? If you have a template for the grapics to share that would be great!

[Pioneer4x4]

Here are scans of 2 of the overlays after being cut. I made the tabs a little longer, they work fine at that length, and are easier to insert. I didn't bother with the Joystick one, all it is, is just 2 holes...

Edited June 30, 2012 by Pioneer4x4

[Pioneer4x4]

looks like the basic shapes included on the $99 cricut will work to assemble a decent overlay.

would it do the fancy ones too like for space shuttle, or star trek i wonder.

The one I have can cut 12" max, but other than that, should be fine. That should be long enough to go around all 6 switches if not fully to the inner corners of the control panel.

[CPUWIZ]

Here are scans of 2 of the overlays after being cut. I made the tabs a little longer, they work fine at that length, and are easier to insert. I didn't bother with the Joystick one, all it is, is just 2 holes...

 

Are they upside down, or was this just a test? Because, wouldn't you need to print it first and then cut it?

[the.golden.ax]

Yes, I have a USB Cricut with sure-cuts-allot software. With effort any shape can be designed and cut with that rig.

[+Nathan Strum]

Tell you what, I'll use those as my first try on the Atari Keypad. What did you use as the diameter on the holes (And how did you cut them, that had to be a PAIN)? I think I worked it out to cut them .375" diameter, and .6" apart.

I used an X-acto knife. Really tedious.

 

Your measurements should work fine. The hole diameters I had were a fraction smaller, but not enough to make any difference.

 

I've attached the Adobe Illustrator file (CS5). There's a "Holes" layer which shows what I had cut out. If you don't have the fonts, there's a "Text as outlines" layer, so you can still print the document. If you don't have Illustrator (or CS5) let me know what format you can use, and I'll see what I can do.

 

synthcart keyboard overlay.ai.zip

[Pioneer4x4]

Great, I'll try to work something up. I have Corel Print Shop 5 (I think)

[Pioneer4x4]

Are they upside down, or was this just a test? Because, wouldn't you need to print it first and then cut it?

Just a test, I went through quite a bit getting all of the dimensions sorted, and getting the damn holes lined up with the actual buttons.

[Pioneer4x4]

 

I've attached the Adobe Illustrator file (CS5). There's a "Holes" layer which shows what I had cut out. If you don't have the fonts, there's a "Text as outlines" layer, so you can still print the document. If you don't have Illustrator (or CS5) let me know what format you can use, and I'll see what I can do.

 

synthcart keyboard overlay.ai.zip

I have Corel PaintShop Pro X4, and it was able to open it and make a raster image of that, no layers. I made it at 300 DPI and filled in the circles with neighboring colors, then did a VERY quick print and cut.

• The material you are cutting is held on a sticky mat, so I have to put the photo paper glossy side down, the back side doesn't stick.
  
• Since you have to print first, then cut, you are putting it on face down, so alignment is going to be a REAL pain for something detailed, especially on the Atari Keyboard.
  

Luckily the ink did not transfer to the sticky mat, and it cut fine, alignment was off (which I expected) and scale was off (I need to figure that out), BUT ignoring all of that... They look like they will work out nice.

I won't bother scanning them yet since they are so far off.

[Pioneer4x4]

My last try of the night, I give up for now.

Scale seems OK, cutting seems OK, spacing on them both seems OK, just overall alignment sucks.

 

And cut time for both is less than a minute!

[snstay]

looks good! your hard work will pay off.