How to Make Laser Engraved Key Fob (Free Cut Files)

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How to Make Laser Engraved Key Fob (Free Cut Files)

Learn how to make leather key fobs for vehicle owners, home owners or anyone with a new key using a laser engraver and cutting machine.

If you love quick laser projects that feel polished, giftable, and just a little bit fancy, these faux leather key fobs are going to be right up your alley.

They’re fast to make, endlessly customizable, and a fantastic way to turn small scraps of material into something practical and beautiful.

For this project, I used my xTool S1 laser cutter to cut and engrave faux leather key fobs made from leatherette from Houston Acrylic.

The laser handles both the shape cutting and the engraved details, giving you crisp, professional results every time.

Even better, I designed three different key fob styles, and I’m sharing them as a free xTool cut file download so you can make your own.

Let’s walk through the entire process step by step.

For this project, I used my xTool S1 laser cutter to cut and engrave faux leather key fobs made from leatherette from Houston Acrylic. The laser handles both the shape cutting and the engraved details, giving you crisp, professional results every time. Even better, I designed three different key fob styles, and I’m sharing them as a free xTool cut file download so you can make your own. Let’s walk through the entire process step by step.

Why Faux Leather (Leatherette) Works:

Faux leather—often called leatherette—is one of my favorite laser-friendly materials.

Unlike real leather, it’s consistent in thickness, engraves cleanly, and cuts beautifully without a lot of guesswork.

I used Houston Acrylic leatherette for these key fobs, and it was perfect for:

Clean, precise laser cuts
High-contrast engraving
Folding neatly without cracking
Creating sturdy but lightweight key fobs

It’s an excellent option whether you’re brand new to laser crafting or already deep into it.

Why Faux Leather (Leatherette) Works: Faux leather—often called leatherette—is one of my favorite laser-friendly materials. Unlike real leather, it’s consistent in thickness, engraves cleanly, and cuts beautifully without a lot of guesswork.

Supplies Needed for Laser Engraved Key Fob:

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Faux leather / leatherette sheets
Rainbow double cap rivets
Rainbow O-rings OR Rainbow O-Ring Clips
Rubber cement
xTool S1 laser cutter
xTool Creative Space software
Small rubber hammer
Soft cloth for cleaning
Free xTool key fob cut file (includes 3 styles for xTool and SVG's)

<<FREE CUT FILE OPT-IN AT THE END OF THIS POST>>

Step 1: Download and Open the Free xTool Cut File

Start by downloading the free key fob cut file.

It includes three different faux leather key fob styles, each designed to work with standard key fob hardware, rivets, and O-rings.

Open xTool Creative Space and import the file:

Duplicate designs for batch cutting
Resize slightly if needed
Swap out the engraved design or add text

Make sure engraving elements are set to Engrave and outline paths are set to Cut.

Step 1: Download and Open the Free xTool Cut File Start by downloading the free key fob cut file. It includes three different faux leather key fob styles, each designed to work with standard key fob hardware, rivets, and O-rings. Open xTool Creative Space and import the file: Duplicate designs for batch cutting Resize slightly if needed Swap out the engraved design or add text Make sure engraving elements are set to Engrave and outline paths are set to Cut.

Step 2: Customize the Engraving

This project is perfect for personalization. You can engrave:

Small illustrations
Names, Monograms or initials
Short words or phrases
Simple icons
Hand drawn art

Faux leather engraves beautifully, so even small details show up clearly.

Keep designs simple for the best contrast, and always do a quick test engrave on a scrap piece if you’re trying something new.

Step 2: Customize the Engraving This project is perfect for personalization. You can engrave: Small illustrations Names, Monograms or initials Short words or phrases Simple icons Hand drawn art Faux leather engraves beautifully, so even small details show up clearly. Keep designs simple for the best contrast, and always do a quick test engrave on a scrap piece if you’re trying something new.

Step 3: Set Up the xTool S1

Place your leatherette onto the laser bed of the xTool S1.

If the material isn’t laying completely flat, use magnet clips to hold it in place.

Suggested Starting Settings (Always Test First)

These can vary slightly based on color and thickness:

Engrave: 20–30% power, medium speed
Cut: 100% power, slower speed, 1–2 passes

Once your settings are dialed in, you’re ready to start.

Step 3: Set Up the xTool S1 Place your leatherette onto the laser bed of the xTool S1. If the material isn’t laying completely flat, use magnet clips to hold it in place. Suggested Starting Settings (Always Test First) These can vary slightly based on color and thickness: Engrave: 20–30% power, medium speed Cut: 100% power, slower speed, 1–2 passes Once your settings are dialed in, you’re ready to start.

Step 4: Engrave and Cut the Key Fob Shapes

Run the engraving first, followed by the cut pass.

The xTool S1 cuts faux leather cleanly and leaves smooth edges that don’t need any additional finishing.

When the laser is finished, carefully remove the key fob pieces from the bed.

If there’s any residue from engraving, gently wipe it away with a soft cloth.

Step 4: Engrave and Cut the Key Fob Shapes Run the engraving first, followed by the cut pass. The xTool S1 cuts faux leather cleanly and leaves smooth edges that don’t need any additional finishing. When the laser is finished, carefully remove the key fob pieces from the bed. If there’s any residue from engraving, gently wipe it away with a soft cloth.

Step 5: Attach the Rainbow O-Ring

Slide a rainbow O-ring through the top opening of the key fob by rolling up the leatherette and slipping it through.

This is where your keys will attach, and it also adds another colorful, modern detail to the design.

I'm using solid O-rings, but you could use O-ring clips for single loop keychain and attach the keys directly to it.

Step 5: Attach the Rainbow O-Ring Slide a rainbow O-ring through the top opening of the key fob by rolling up the leatherette and slipping it through. This is where your keys will attach, and it also adds another colorful, modern detail to the design. I'm using solid O-rings, but you could use O-ring clips for single loop keychain and attach the keys directly to it.

The key fob will fold over at the center, lining up the cut holes and wider, engraved portion.

Step 6: Glue the Key Fob Halves Together

Each key fob is designed to fold in half around the hardware, creating a clean, finished look.

Apply a thin, even layer of rubber cement to the inside of both halves of the faux leather piece.

Let the adhesive become tacky according to the manufacturer’s instructions, then carefully fold the key fob in half, aligning the holes perfectly.

Press both halves together firmly and allow the rubber cement to set.

This step helps keep everything aligned and secure before adding the rivets.

Step 7: Set the Rainbow Double Cap Rivets

Once the glue has set, it’s time to permanently secure the key fob.

Insert rainbow double cap rivets through the pre-cut holes.

Place the rivet caps on both sides, then just a few firm taps with a hammer will set them in place.

This will create a strong, professional-looking finish.

The rainbow rivets add a fun pop of color and instantly elevate the finished key fobs.

The key ring is permanently in place and easy to a keyring and all the keys to.

Works great for a zipper pull on a duffle bag or even as a luggage tag too!

Step 8: Make a Set (or a Whole Bunch!)

These key fobs are incredibly quick to batch-make once you’ve done one. Try:

Mixing different faux leather colors
Pairing contrasting rainbow hardware
Using different engravings on the same shape
Creating coordinating gift sets

The three included key fob styles give you plenty of variety while keeping everything cohesive.

Step 8: Make a Set (or a Whole Bunch!) These key fobs are incredibly quick to batch-make once you’ve done one. Try: Mixing different faux leather colors Pairing contrasting rainbow hardware Using different engravings on the same shape Creating coordinating gift sets The three included key fob styles give you plenty of variety while keeping everything cohesive.

Ideas for Using Faux Leather Key Fobs

These laser-cut key fobs make wonderful:

Handmade gifts
Teacher or neighbor gifts
Party favors
Craft fair or small shop items
Personalized accessories for bags and backpacks
Luggage tags

They’re lightweight, durable, and feel surprisingly high-end for such a simple project.

Ideas for Using Faux Leather Key Fobs These laser-cut key fobs make wonderful: Handmade gifts Teacher or neighbor gifts Party favors Craft fair or small shop items Personalized accessories for bags and backpacks Luggage tags They’re lightweight, durable, and feel surprisingly high-end for such a simple project.

Pick whatever design you want on your keychain key fobs, I'm using stock shapes and fonts directly from xTool Creative Space but you can design all your own!

That's it!

Faux leather key fobs are one of those laser projects that check all the boxes: quick to make, highly customizable, and genuinely useful.

Using the xTool S1 laser cutter, Houston Acrylic leatherette, rubber cement, and rainbow hardware makes this project both beginner-friendly and visually striking.

Be sure to download the free xTool key fob cut file with all three styles and experiment with different colors and engravings to make them completely your own.

Happy laser crafting! 🌈✨