Decorative Laser Cut Air Return Covers and Quilted Appliqués

So we’ve been having a little fun today doing some decorative yet utilitarian designs for our house. A few years back I saw these custom air return grates that were just so much prettier than the metal slat style we have but it was going to be pricy to do the whole house; consistency is key with these things given how open our architecture is. But now, well, lumber is a lot more expensive than it used to be but still more affordable than buying these made to order. So off we went!

Let it be said that my sewing room/studio and the craft room (yes I need two rooms and yes, they’re both full) are places of fun and creative flow for me, so my approach is unrestrained in my sewing room ????. I’m attaching a video that was recorded without sound for context. For anyone wondering, no, the rest of the house isn’t orange. The video starts in my fabric closet.

This explains the whimsy

Now for the air return cover!

Yay!

We went with a more geometric design for the rest of the house. Eventually the vents on the ceilings, walls, and floors will all be done in this design. I’ll stain the ones for the floors to match the hardwood. The covers for the walls and ceilings will be in high gloss white to make them easy to rinse off. I might even coat them in some clear PolyCrylic for good measure.

Covers for the rest of the house
Bright white air return vent covers

In addition to the wood projects I wanted a few new designs for my greeting cards so I chose a couple of bird vector files. One was easy to export but another gave Cameron a bit of a tussle. But as always, my hero prevailed! He amazes me ????

New quilted shapes for my greeting cards. They would make beautiful appliqués too! Hmmmm!

I tried using an AI art app to create some original vector files and had a few cool designs come out before the app stopped working. Anyone out there using generative AI for vector files, give me a holler. I’m willing to pay for access if it will follow prompts to create the images. Here are a few that came out.

AI Art
This is what the app made when I uploaded my original hand drawn heart vine. I thought it was pretty cool.
I really like this one and would use it for all of the air vent covers if Cameron was, um, girly, but he’s all dude so geometric it will be!
So many birds! I’m seeing these in all kinds of saturated batiks done as dimensional appliqués on a quilt with a solid background. I think I’d mix in a seagull silhouette and a chickadee!

My sewing friends will be interested in the percentage of waste with these. Cameron fits them as closely together as the shapes allow; I’m starting with randomly sized scraps from other projects so each beginning canvas is a different size (and I only did blues today) so my guess on waste is about 15% with this run. If I did even half yards he could lay them out, mirrored, more closely together but I really didn’t have a plan beyond denting my scrap bin and creating something that is both pretty and useful! Mission accomplished!

Oh, and for anyone cutting quilted shapes like this, our settings are 20% power at 200 mm/sec and three passes for indiscernible char.

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  1. Mindy

    Gorgeousness!!!
    I’d like to say I’m not jealous, but I’m soooo jealous.
    The grate covers are works of art! I’m beyond impressed. Those birds, wow.
    Did I tell you how jealous I am…LOL

    1. Cameron’s Rezo Laser Build

      Thanks Mindy ????. You probably know that the birds and grate covers are standard SVG files but the one for my sewing room is a Silhouette SVG that I customized so I can’t take much credit for the artwork. And Cameron is the one making all of the computer stuff sing. At some point we will offer some stuff for sale but I don’t have a sense of what folks like. It would all be made to order stuff. Do you think people would want those grates if the came unfinished? It’s very time consuming to paint them; I think we could do something like that for local folks if they were willing to pick up and finish them in what ever color/paint finish they wanted.

      1. Mindy

        I would think they would be very easy to sell. If unfinished, people could finish them as they like.
        I’m so excited for you, and what fun to do all this together.

      2. Cameron’s Rezo Laser Build

        Interesting. I’m sure there are standard sizes for air return grates. Maybe a list of the sizes with corresponding pricing and a requirement for pre-payment and local pickup? We do have fun together and he indulges all of my sewing stuff with such patience. The novelty hasn’t worn off and I squeal and clap when stuff like the sewing room vent gets cut ????.

      3. pinterella1940

        These are so special!!! You 2 are so creative!!!

  2. pinterella1940

    Fabulous!!!! You 2 are quite the team! Your work admirable. Love u, Mum

    1. Cameron’s Rezo Laser Build

      Thanks mum; we have fun together.

  3. pinterella1940

    I love that bent in your sewing room!’ A Winner!!!

    1. Cameron’s Rezo Laser Build

      I think you’re a few posts behind but thank you. Cameron did the kitchen, our bedroom, and the one on the ceiling by the craft room.