Customizable 3D Printed Poker Chip (Multicolor With Single Extruder!)

This instructible will teach you how to design and 3D print a custom poker chip (or coin) with a multicolor design using a Fusion360 file I provide. This coin can be printed on a basic 3D printer using only a single nozzle, no multimaterial upgrades necessary!

The techniques used in this tutorial can be used to create other multicolor 3d models with even more colors.

1. 3D Printer (FDM)
2. At least 2 different colors of filament
3. Permanent Adhesive (Superglue, Epoxy Resin, etc)
4. A penny or other coin (optional for weight)
5. Fusion360
6. An SVG file of your image/design
7. Sandpaper

The first step is to download and open the attached Fusion360 file. Once you have opened the file, you can easily configure the chip by changing the parameters.

Go to Modify > Change Parameters. Then click on the arrow next to Favorites to show the favorited parameters. Notice the names, units and expression for each parameter. You can modify the size of the chip by adjusting the values shown.

(For reference, a typical poker chip is about 39mm in diameter and 3.3mm thick. Since the poker chip will printed as two halves, the thickness of the chip is 3.3/2 = 1.65mm by default. Additionally, the pocket in the middle is for placing a coin inside the chip to give the chip additional weight. The default parameters are for fitting a US penny)

Now rotate the model in Fusion360 and select the face of the chip. Then click Insert > Insert SVG. Choose the SVG file you want to use and then click Insert. I'm going to be using an SVG of North Carolina.

When Fusion360 opens you're SVG, it likely will not be scaled or positioned correctly. Don't worry about positioning it yet, just click Okay on insert dialogue box.

In the sketch view, the SVG will have green outline. Click and drag to select the entire outline, the Right Click and click Fix/UnFix. Now the svg should have a blue outline. Next click Create > Point, and place a point in the center of your svg. Now select the outline and the point, click Modify > Move/Copy.

Set Move Type as Point to Point

Set the Origin Point as the Center Point you created

Set the Target Point as the Center of the Chip

This will automatically move the SVG to be centered on the face of the chip. Click Okay.

Scaling the SVG will be similar to moving it. Select the outline of the SVG and the center point. The click Modify > Sketch Scale. Click the Center Point as the scaling point. Now enter a number to rescale your svg. The scale number is relative and does not reflect exact dimensions. I scaled my svg by 0.80 to reduce its size.

Once the svg has been positioned and scaled, click Finish Sketch.

The design needs to be separate from the chip so that we can set the print up correctly in the slicer.

Click Create > Extrude, and select the region within the SVG outline. Set the extrude distance to either -0.2mm (for one layer) or -0.4mm (for two layers). Then set the operation as Cut. Click Okay.

Next, on the component tree of the top left of your screen, click the arrow next to Sketches, then click the Show/Hide icon next to Sketch3 to show it.

Repeat the extrusion of the SVG using the same distance, but this time choose New Component as the Operation. This should fill in the region you previously cut away. I recommend giving the new component a name so that you can identify it in the slicer. I renamed mine to State.

If you haven't already, save the file in Fusion. Then click File > Export. Then choose STEP as the file type. (STL will work as well, but a STEP file will be slightly easier to work with in the Slicer)

I am using Prusa Slicer (version 2.9.0). This will probably work in other slicers, but I will not provide instructions to do this with other slicers.

Open the step file in Prusa Slicer. Notice on the right side of the screen that underneath the file, there are two parts. The first part should be labeled "Solid", and the second part should be labeled whatever you named the new component. In my case, the second part is labeled "State".

Remember that each part is only half the chip, so copy and paste a second chip into the slicer.

If you want to rotate or reposition the part on your print bed, do it now. (If your printer homes or self-levels itself before each print with a probe, move the chip so that it is positioned when the probe will NOT measure the bed).

Delete the "Solid" part from both chips in the slicer. This should leave just the design on the printer.

Slice the print with a 0.2mm layer height. DO NOT use a brim or a raft. Skirts are okay

*Important: make sure your printer's travel height is greater than the thickness of the design. 0.8mm is a safe travel height to use. To check, go to Printers > Extruder 1 > Travel Lift > Lift Height).

Now just export and print!

Print the design. Once it is finished, DO NOT REMOVE THE COMPLETED PRINT. If you printed a skirt, remove it carefully, but it is essential that the print remains attached to the print bed.

If you use a heated print bed, heat it back up after the print finishes to prevent the print from detaching itself.

In Prusa Slicer, undo your change (CTRL+Z or Edit > Undo) until the "Solid" parts are back. This time delete the "State" parts. Now slice the chips. You should see the first layer (or two if you used 0.4mm thickness for the design) is empty where the design is. Export the gcode file. Make sure you change your filament color before printing.

Once the print is complete, you can remove the everything from the print bed. The design should be fused to the chip halves.

*Important: Make sure you do not have supports enabled.

Gently rub the inside faces (not the faces with the design) against sandpaper to help smooth the surfaces. Wipe away any dust.

Next, place your coin in the coin pocket (optional), and apply a few drops of adhesive. Align and press the halves together according to the instructions of your adhesive. Once finished, your chip is complete!