From a design to a stack of 0.2 mm layers.

Your choices in the designer are numbers: diameter, thickness, the pattern on each part of the face, the rim pattern, colours, core. The designer turns them into the shapes the printer will build.

The body is a disc with a chamfered edge. If you chose a core, a pocket is cut into the middle. The patterns are drawn as flat outlines and cut into the surface as inlay.

A printer builds a part by laying down melted plastic, 0.2 mm at a time. A 3.4 mm chip is 17 layers. Figure 4 shows them.

Four layers form the bottom skin, 0.8 mm. Nine layers surround the core pocket, 1.8 mm. Four more close the top, 0.8 mm.

A standard core is a metal disc in a pocket of Ø25.2 × 1.8 mm, centred in the chip. The heavy core sits in a pocket of Ø27.8 × 2.0 mm.

The printer pauses when the pocket is open. The disc is placed by hand and the print resumes, building the top skin over it. The skin on each side of the pocket is at least 0.6 mm, so the core is sealed in.

The core is what takes a chip from about 5 g to about 10.3 g.

The printer changes filament during a print. That is how colour gets into the chip without paint or stickers. On the face, the last two layers, 0.4 mm, carry the pattern colour and are flush with the surface.

The rim has its own inlay, 0.6 to 1.5 mm deep, measured inward from the edge. A chip can use up to three colours. The printer holds four spools and one slot stays free for changes.

Each set is checked and packed by hand before it ships.

Expect 0.2 mm layer lines on the rim, and sizes within ±0.3 mm.