How We Design Our Laser-Cut Pieces (And Why Some Ideas Never Make It)
People ask us all the time: “Where do your laser-cut designs come from?” The honest answer? Everywhere and nowhere. Here’s the real process behind those laser-cut pieces you see in our Saskatchewan shop.
The honest answer? Sometimes it’s a Saskatchewan highway sign that sparks an idea. Sometimes it’s a custom order request that gets us thinking. And sometimes it’s 2 AM and we’re wide awake with a sketch that either turns into our next bestseller or gets filed under “what were we thinking?”
Here’s the real process behind those laser-cut designs you see in the shop.
The Five-Step Design Process for Custom Laser-Cut Pieces
Step 1: The Idea (The Easy Part)
Ideas are cheap. We have hundreds of them. A wheat sheaf mug design. A custom lake sign. A prairie sunset coaster set. Most of them sound brilliant at midnight and questionable by morning coffee.
The hard part isn’t coming up with ideas—it’s figuring out which laser-cut designs are worth making.
Step 2: The Sketch (Where Things Get Real)
We start on paper. Always. Even though we have fancy design software, there’s something about putting pen to paper that helps us think through whether an idea actually works.
Questions we ask at the sketch stage:
- Is it too detailed for sublimation printing?
- Will it look good at 3 inches? At 12 inches?
- Does it feel distinctly prairie, or could it come from anywhere?
- Can we laser engrave this on wood without losing detail?
If it passes the sketch test, we move to the computer.
Step 3: Digital Design (The Technical Stuff)
This is where we build the actual file that tells our laser cutter what to cut. We use vector software (Adobe Illustrator, if you’re curious) to create clean, precise lines.
Every curve matters. Every measurement matters. A line that’s too thin won’t cut properly. A laser-cut design that’s too intricate will look muddy on a mug.
We also have to think about production:
- Can we cut this efficiently with our laser engraving equipment?
- Will it warp during the sublimation process?
- How will it sit on different products?
- Does it work for both mugs and signs?
Step 4: The Prototype (Where Dreams Meet Reality)
We never skip this step. Ever.
We cut a test piece with our laser cutter, sublimate it onto a sample product, and live with it for a few days. Does it look good in person, or just on screen? Does the scale work? Does it feel right?
Some designs nail it on the first try. Others need three rounds of tweaking. And some? They go straight into the “nice try” folder.
Step 5: Production (If It Makes the Cut)
If a laser-cut design survives all of that, it goes into production. We cut the pieces in batches, sublimate them onto mugs or signs or whatever we’re making, and add them to our handmade gift shop.
But even then, we’re watching. Does it sell? Do people connect with it? Does it hold up over time?
If the answer is no, we pull it. We’re not interested in making things people don’t actually want.
What Doesn’t Work (And Why We Don’t Make It)
We get requests for designs we can’t or won’t make:
- Overly trendy stuff: If it’ll look dated in six months, we’re not doing it.
- Too generic: If you can buy it at Walmart, why would you buy it here?
- Technically impossible: Some things just don’t work with laser engraving, no matter how cool they’d look.
- Against our brand: We’re prairie-focused, Saskatchewan-made. We don’t do palm trees.
We’d rather make fewer laser-cut designs that actually matter than flood the shop with things we’re not proud of.
The Designs That Surprise Us
Some of our bestsellers weren’t the ones we expected. That simple Saskatchewan highway sign design? We thought it was too plain. Turns out, people love it.
That elaborate prairie landscape? We thought it was our masterpiece. It sits in the shop collecting dust.
You never really know until you make it.
Why We Design Our Own Laser-Cut Pieces
We could buy stock designs. Lots of laser cutting businesses do. But that’s not what Grey Barn Handwerk is about.
Every design in our shop is something we created, tested, and decided was worth making. It’s all Saskatchewan-made, woman-owned, and zero corporate BS.
When you buy a laser-cut mug or sign from us, you’re not getting something from a catalogue. You’re getting something we actually designed and made in St. Gregor, Saskatchewan.
Want to See the Laser Cutting Process in Person?
If you’re curious about how we design and make things, come to a Saskatchewan craft workshop. We don’t keep secrets. We’ll show you the whole process, let you use the equipment, and send you home with something you made yourself.
No corporate polish. No Instagram filters. Just the real, messy, rewarding process of making something with your hands.
Frequently Asked Questions About Our Laser-Cut Design Process
Do you take custom laser cutting requests?
Sometimes. If it fits what we do and we think we can do it well, yes. If it’s outside our wheelhouse or doesn’t match our brand, we’ll be honest and point you in the right direction. Submit a custom order request and we’ll let you know.
How long does it take to design a new laser-cut piece?
Anywhere from a few hours to a few weeks. Simple designs can happen quickly. Complex designs with multiple prototypes take longer. We don’t rush it—if it’s worth making, it’s worth making right.
Can I suggest a design idea?
Absolutely. We’ve created some of our best pieces based on customer ideas. Reach out at [email protected] and let us know what you’re thinking.
Where can I buy your laser-cut designs?
Right here in our online shop. We ship across Canada. Everything is made to order in St. Gregor, Saskatchewan.
