How to Make Fallout Miniature Vault Door Ornament DIY

Learn how to make a laser-cut, hand-painted, distressed, post-apocalyptic Fallout inspired miniature world with Free Files Included at the end of post!

FALLOUT WORLD MINIATURE

There’s something uniquely charming about mixing the rugged, retro-futuristic aesthetic of the Fallout universe with handmade, tactile crafting techniques. 

    
The franchise’s blend of whimsical Americana, worn metal textures, and bright pops of color creates an irresistible playground for makers—especially for those of us who gravitate toward laser-cutting, miniature builds, and dimensional designs. 

Let's get started!

Today, I’m excited to walk you through a full tutorial for creating my layered Vault-inspired hexagon hanging ornament, complete with a wood-cut balloon cluster reminiscent of Reclamation Day festivities.

At the end of the post, you’ll also find the free files I designed so you can make your own.

Supplies Needed for Miniature Fallout Vault Door Ornament:

Here’s everything I used to complete this project. If you don’t have all the exact brands, feel free to swap in what you prefer—it’s very flexible.

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• xTool S1 20W (or similar diode laser cutter)
• 3mm basswood sheets
• Arteza Acrylic Markers (assorted colors)
• Distress ink or watered-down brown/black acrylic paint for aging effects
• Clear sealant (optional)
• Bearly Art Precision Glue
• Hot glue gun and glue sticks
• Palette, wipes, and paper towels
• Wooden hexagon hanging shape (Michaels)
• Small cluster of reindeer moss in natural green tones
• Masking tape
• Scrap paper for Acrylic Marker test swatches

Step 1: Cutting the Layered Vault Design

To start, load all the free layered files into your preferred laser software at the same time. If you alter the size, do all of the files at once to keep them the same proportions.

The design is intended for 3mm wood, and it cuts beautifully on the xTool S1. Make sure your wood sheet is secured, your settings are dialed in, and your preview matches the board placement.

Before cutting, I usually do a quick visual check to ensure everything is aligned properly. The layered file includes multiple pieces that stack to create depth, shadows, and texture. The design mimics the thick, gear-like framing of a classic vault entrance, with separate rings, internal plates, and small detailing pieces that bring the structure to life.

Once cut, remove your pieces carefully, brushing away any char with a soft cloth. If desired, sand lightly along the edges. Basswood tends to cut cleanly, but smoothing the edges helps paint glide on later.

I selected Vault Door #25, it's not a canonized door at this point, but since Christmas is the 25th, I decided that was the perfect number.

This is where your creativity kicks in—you can stick to game-accurate colors or reinvent the palette. 
I went for a bold metallic look, using deep yellows, steel grays, and muted blues to give that slightly industrial feel while preserving the playful brightness found in Fallout’s retro-inspired design language.

Step 2: Coloring the Layers with Acrylic Markers

Arteza Acrylic Markers are perfect for this project because they offer rich pigments, clean lines, and a smooth matte finish. Plus, they dry quickly and blend surprisingly well on wood.

Begin by laying out your pieces in the order they stack; this helps you plan color transitions. Think about where lighter shades might highlight raised areas and where darker tones might mimic shadows.

I started by coloring the tiniest little numbers, use caution so they don't snap in half!

Then color the outermost ring panel, giving it a warm, aged yellow—something reminiscent of worn caution paint. For the inner rings, I switched to the metallic silver.

The innermost pieces received a darker tone, making them appear recessed. Fallout structures often play with heavy contrast: old metals mixed with bright pops of color. 

Using markers lets you create that comic-book edge while still capturing a gritty, weathered aesthetic.

Once all layers are finished, let them dry completely before moving on.

Step 3: Preparing the Hexagon Hanging Frame

The hexagon wood shape I found at Michaels is a perfect stage for your vault build. Before adding anything inside, give the wood some character. Fallout décor is never pristine; it’s always aged, dusty, and full of stories.

To achieve that look, use either:

• Distress ink pads, or
• Watered-down acrylics in brown, black, or gray.

Gently brush the edges, corners, and interior seams of the hexagon. Allow some streaking and unevenness—messiness actually enhances the aesthetic. You want it to feel like it’s been hanging for decades in a dilapidated structure or discovered inside an old Overseer’s office long after the bombs fell.

After distressing the frame, let it dry fully before adding your vault centerpiece.

This tutorial is not only approachable but also fully customizable, whether you want to re-create mine as-is or adapt the colors, distressing techniques, or additional details to match your personal style. 

I’m using the xTool S1 20W and 3mm basswood for this project, along with acrylic markers, adhesives, and a pre-made wood hexagon shape. 

Everything comes together to make a beautiful, rustic-meets-retro ornament that looks as though it was plucked directly from a display case in Appalachia or the Commonwealth.

Step 4: Gluing the Layered Vault Assembly

After everything dries, it’s time to assemble your layers using Bearly Art Precision Glue. This glue is perfect for intricate laser projects because:

• It dries clear.
• It doesn’t warp the wood.
• The precision tip allows you to apply tiny dots without mess.

Begin from the bottom layer, adding a controlled bead of glue, then placing the next layer on top. Press gently and allow each stack to settle before adding the next. The final assembly should feel sturdy and dimensional—almost like a miniature prop pulled straight from the Fallout universe.

This layered approach not only adds realism but also creates wonderfully dramatic shadows when placed inside the hexagon frame.

Using This Project for Gifts, Collections, or Displays

Whether you’re crafting for yourself, preparing handmade gifts, or building up a themed game room, this project is ideal. 

A single ornament can take center stage, or you can create a collection using different colors, vault numbers, or accessory details like flags, banners, mini crates, or signage.

Use tweezers to carefully set the delicate little laser-cut numbers.

This part is the most critical, because that little detail makes the biggest impact!

Look at the teensiness (absolute tininess) of those numbers!

A Note on Inspiration & Process

When I first sketched out ideas for this layered vault door concept, I thought about all the quirky Fallout references that fans love: quirky advertisements, post-war jingles, dusty terminals, and even the odd caution sheet warning about contact uploading protocols. 

I also thought about how players often jot down a phone number on the corner of a notepad while trying to decode a message, or how they wander into abandoned armor shops hoping to find an overlooked treasure. It's these little world-building details that spark creativity. 

The same charm that comes from spotting a brightly colored xbox design lab controller on a desk in some forgotten settler home, or stumbling upon a mural of the ever-smiling vault boy tucked behind a rusted pipe, inspires makers like me to incorporate subtle nods and playful energy into our own real-world projects. 

Even the idea of a discarded giddyup buttercup toy sitting half-buried in moss next to a derelict wall brings that familiar sense of nostalgia and melancholy that defines the entire Fallout universe.
Feel free to add any other nostalgic Fallout universe pieces to this little dioramma.

Step 5: Mounting the Layered Vault Design Inside

Once your frame is prepped and dry, glue the assembled vault design into the center. 

Bearly Art Glue works perfectly here as well, although hot glue can be used if you prefer a quicker set.

Offset the vault door slightly, so there is room to add balloons and moss...unless you just want the Vault Door, then you can go ahead and center it.

Press down firmly and allow the glue to cure.

The layered structure will instantly catch shadows from the frame, giving your ornament a striking dimensional effect.

Fallout-Inspired Details I Included:

Throughout the piece, I incorporated inspiration drawn from iconic Fallout visuals—without directly copying any assets. Here are some Easter-egg-style touches:

• The color palette echoes in-game tech aesthetics.
• The distressed wood suggests weathering and long-term decay.
• The balloons hint at celebration amid turmoil.
• The moss adds that reclaimed, post-human vibe.
• The vault structure honors one of the most recognizable symbols in the franchise.

Crafting a piece like this isn’t just about building décor—it’s about capturing a world.

Look at that glorious Vault door!

Seriously, Vault-Tec would be real proud of me!

Step 6: Cutting and Coloring the Balloon Cluster

Now for the fun, celebratory part—the miniature balloon cluster! 

This little detail completely changes the tone of the piece, transforming it from a serious industrial object into something festive and full of story. 

For this, I cut a small balloon bunch out of 3mm basswood using the same laser settings. 

Because the piece is small, make sure your speed is balanced so edges don’t over-char.

This cheerful balloon grouping echoes the cheerful, slightly uncanny optimism of pre-war propaganda posters and Reclamation Day festivities.

Use your acrylic markers again to color the balloons. 

I went with bright hues, in true Vault-Tec style, and did 2 blue balloons and one yellow one, with some color blending.

This ornament can be utilized a variety of ways:

• Hanging on a holiday tree
• Sitting on a shelf beside your gaming setup
• Paired with memorabilia or collector’s figures
• Hung on a reclaimed wood backdrop
• Displayed near Fallout art prints

Its blend of colors, textures, and materials makes it uniquely eye-catching, even among other handmade projects.

Don't forget a little highlight splash on the edge of the balloons!

I love this little bundle of balloons, I really feel like this finishes off the ornament.

Allow the balloons to dry, then glue them carefully onto one side of the framing interior with hot glue so they immediately hold their place. 

You want them to feel like a subtle but intentional detail—quirky, bright, and symbolic of hopeful beginnings in a chaotic wasteland.

Step 7: Adding Moss Overgrowth for Post-Apocalyptic Texture

To really sell the “abandoned for decades” look, add small patches of reindeer moss around the frame using hot glue. 

I like to tuck it around the base of the balloons and a little along the top, as though nature has slowly crept in over time.

The moss creates a striking contrast with the bright balloons and layered metal-like vault structure. 

This juxtaposition—nature reclaiming technology—is a subtle narrative element that fits perfectly with Fallout storytelling.

Just a little goes a long way here; don’t cover too much of your design.

Why a Vault-Themed Ornament?

The Fallout universe has always blended nostalgia with survivalism, and it’s this quirky mix that has inspired countless makers, gamers, and cosplayers. When you think about Fallout, a few iconic visuals come to mind: the bright blue and yellow jumpsuits, the cheery thumbs-up of a certain mascot, the bold numbering of a Vault entrance, and the celebratory yet slightly eerie festival decorations from various in-game events.

While browsing craft supplies at Michaels, I found a wooden shadowbox-style hexagon with an open front. Immediately, I envisioned it as a perfect framing piece for something industrial and symbolic—something that might be hanging in a Nuka-Cola bottling plant break room or sitting on a dusty shelf in a forgotten Overseer’s office. A layered vault design felt perfect. With multiple cut layers, painted details, and distressing, it captures that unmistakable Fallout aesthetic. 

And with Fallout 76’s Reclamation Day vibe in mind, I knew it needed one more playful detail: a small cluster of balloons to echo that sense of new beginnings amid chaos.

Step 8: Final Touches & Sealing

If you want to preserve your paintwork long-term, you can lightly mist the piece with a clear matte sealant. 

Make sure to keep the can at a distance so the force of the spray doesn't disturb the moss or the paper-thin layers of distressing.

Add your hanging string or ribbon to your ornament if you are using a different base than me...or just enjoy that your amazing ornament is ready to display!

This project was an absolute joy to create—from the quiet hum of the laser cutter shaping each layer to the moment I glued the final moss patch in place. 

It’s the kind of craft that blends fandom, storytelling, and hands-on artistry into one cohesive piece. 

The result is a whimsical ornament full of dimension, character, and charm.

That's it!

I hope this tutorial helps you create your own version of the Vault Door ornament!

Whether you hang it on your tree, display it year-round, or gift it to another Fallout fan, it’s sure to spark conversations and admiration.

When you make yours, I’d love to see it! Feel free to share your photos and tag me @doodlecraft so I can cheer on your creativity.

Happy crafting—and enjoy your journey into the wasteland of laser-cut artistry.

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Download Your Free Layered Files

As promised, here is the free downloadable file set I designed specifically for this project. 

You can use it with your own laser cutter, modify it, or adapt it to new materials. 

I genuinely love sharing designs that help other makers bring their creativity to life.

Get the FREE Vault Door cut files here:

Whether you're a longtime crafter, an enthusiastic Fallout fan, or both, this design is meant to spark inspiration and give you a starting point for your own imaginative builds.

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