This project is a CNC-machined brass relief inspired by the artwork of a Mario Pikachu Pokémon card. It is designed as both a decorative collectible and a practical demonstration of producing a highly detailed 3D relief in brass with the Carvera.

I first optimized the original image to make its shapes, depth transitions, and fine details more suitable for CNC relief machining. I then generated the 3D model and refined it further to improve machinability while preserving the recognizable details of the original artwork.

The finished piece was machined from 5 mm-thick brass stock. The model height was set to 4.67 mm, leaving a 0.33 mm safety layer beneath the thin background. A spoilboard and double-sided tape were used for workholding, and Auto Level should always be performed before machining.

The model can be scaled proportionally to fit different stock sizes. However, because the background is very thin, makers must recalculate the remaining bottom allowance and verify the maximum cutting depth whenever the model or material thickness is changed. The provided files were prepared and tested for my 5 mm brass setup, but the toolpaths should still be previewed and checked before running them on another machine.

For finishing, I initially tested a single-flute 30° engraving bit with a 0.3 mm tip, but it did not produce the desired surface quality in brass. A two-flute 1.5 mm ball nose bit for metal produced a much cleaner and more consistent finish. I strongly recommend using a new or very sharp finishing tool to preserve the small details in the relief.

I also created a matching Luigi Pikachu brass relief, which is available as a separate project. The two designs can be machined individually or displayed together as a themed pair.

Mario Pikachu Brass Relief Card

Mario Pikachu Brass Relief Card

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