This lasercut world map is based on Buckminster Fuller's dymaxion projection. It uses two layers of 1/8" (3 mm) plywood for the frame and cork for the land masses. The cork allows pins to be stuck in the map to mark places you've visited; threads between those pins can mark out flights, or pin photos in memorable places. All cut files are included in this instructable, so you can freely make your own.

The projection is generated by mapping the world on to an icosahedron (resulting in considerably less distortion than the Mercator and many other projections), and unfolding it in such a way to feature largely contiguous land masses (see animation above).

Supplies

1/8" (3 mm) plywood
1/4" (6 mm) cork underlayment
Wood glue
Pins

Step 1: Design

I went looking for a freely available dymaxion map and found one at http://narukawa-lab.jp/archives/dymaxion-map/. It required editing to reduce the number of cuts the laser cutter needed to make. I simplified the line, then made a negative offset line (which deleted all of the tiny islands) followed by a positive offset line of the same amount. The files I used are attached. Resize to fit your lasercutter as needed.

Step 2: Lasercut

There are 3 laser cutting files (in .svg, .cdr or .ai formats): one for the base (3 mm plywood), one for the oceans (3 mm plywood), and one for the land (6 mm cork). The base and land (cork) both involve simple through cuts, but the oceans have a mix of cuts (black) and lines (red). The lines should be cut at a high speed/low power setting so they score but do not cut through the surface.

Take care with the cork - I used an offcut of cork underlayment that was not very flat and it did not cut especially cleanly. The cork is also prone to burning, so watch the cut process closely.

Step 3: Assemble

Glue the oceans to the base using wood glue and clamps/weights. Then glue the cork land masses in place. The smallest islands can be a nuisance, but don't worry if a few are missing.