I have tried making my own counters multiple times, and its always a huge pain. The hardest part is finding something that can cut 2mm chipboard reliably and accurately. I have a laser engraver, that after a dozen attempts I got to cut black acrylic *perfectly* into .5" square counters. They are durable, thick, easy to pickup, and though sharp edges now I could round them easily enough. However, each 12"x12" black acrylic sheet is like $15, it takes an hour or so to cut, and once cut, all the counters just fall out. So it isn't a "countersheet" IMO.

While I'm not 100% sure this will work, I'm going to start with the die as shown below, and probably buy the GrandeMARK 2 Die-Cutting Machine which the template is made to fit. That machine has 2000psi, so hopefully its enough! This is my primary concern. If it doesn't work, I'll look into die punching machines for leather.

If this works, my other template for .75" hexes, .75" squares, 1" hexes, 1"x.5" rectangles, and so forth, should be pretty easy in comparison and I'll order them all.

Currently I have a color laser printer that I can print both sides on labels to stick, though I may have to tinker with that as they current smear a little. This may end up just being regular paper and some spray glue.

This is for limited prototype purposes for just personal use, and maybe a few testers.

But if it all works great, I'll post links to everything for others so they can make their own counters.

My current parts list:

$200 Template Below (https://www.customshapepros.com/)

$715 GrandeMarke 2 Cutter (https://accucut.com/products/grandemark-2-die-cutting-machine)

$30 for a 100 pack of 50pt/2mm chipboard (https://www.amazon.com/gp/product/B0849PMMQG)

Overall cost per countersheet once the template/cutter are paid for is under $1!

I make the counters using visual basic .net. I create a bitmap, then draw the counters at proper intervals using an excel spreadsheet source (that may point to other images). The logic around them is not that hard, and I've made dozens of countersheets programmatically over the years.

Crossing my fingers this cutter cuts it out!

https://preview.redd.it/exzpdsb99ywd1.png?width=2111&format=png&auto=webp&s=c7e4033727db9a48da5b8a28d3ac1a869edfca66