For cutting the cork circles I would try hollow punches first, especially if they are fairly small circles.

 

Not that small ... probably 4" circles. Maybe 4" rectangles with rounded edges.

 

I've never had much luck cutting cork, except with sharp scissors. Quick search on the drone-powered shopping site and I found 1/8" thick 4" round cork at $12.99 for 24 (shipped), so it works out to $0.54 each. Cutting sheets may be cheaper on the surface, but I think i'd experiment with cutting methods before buying bulk sheets. Reading Charles' comment i'd bet on production pieces of cork being stamped.

Good luck!!
earl

 

I think you might have to sandwich it between two sheets of something to cut it Henry. Or glue the cork to something stiffer first. I think I might try to find a 4" pipe or steel tube and sharpen the edge and turn it into a hollow punch.

 

a while back, I took a bunch of scraps and glued em up to make a few cutting boards and such.... then I thought to use the scraps from the scraps. Figured what the hell, make a few coasters with my grandson. 20 in total. just shy of 4"s in dia. 1/8"+ thick. Cork seemed to be the logical choice for the bottoms. I picked up some 12" x 12" x 1/8" squares from a local craft store. 4 to a pak. I forget the price, but remember it being reasonable enough.

Applied a liberal amount of spray adhesive to the cork (pretty sure it was 3M super 99) and let tack up. Laid out 5 coasters to a sheet. Sandwiched those sheets between 1/8" plywood. Then the whole package between a couple of 3/4" pieces of ply. Weighted down with a 30lp dumbbell and walked away for a few days. After I was sure everything had set and was dry, cut out the coasters with an scalpel (x-acto knife). Easy enough, nice clean cuts. Then took em over to the 12" disc sander, blended all the edges together then took some 180 and rounded over the bottoms. A few coats of spray on poly and a top coat of wax polish.

Cork will take a nice edge, but I don't think it'll hold up all that well. My experience with the stuff is that it wants to chip away. Rounding over the edges really seems to make a huge difference in terms of longevity. Im pretty sure you'd have the same issues when "stamping" out the cork unless you use some really sharp dies.

 

I have no idea how it would work but how about a scroll saw?

 

Henry you should be able to cut it on a CNC using a sharp down cut bit using a jig to hold the cork. something like this. Run the toolpath, shift the cork in the clamp, run the toolpath, shift the cork .....

 

Buy a laser cutter! LOL
Years ago, I made 100 sets (6 pieces plus a stand with four rounded dowels to hold them) I made these oak coasters for a Junior Achievement group. Used a forsner bit for the recess in 1/2" thick oak squares. We machined a hole saw into a "punch". The folks used a vise to punch out cork disks out of adhesive backed cork sheets. Came out nice!

 

I was cutting some cork for an art project years ago, and after some tear-out, I started using my handy dandy X-acto knife and had nice clean cuts.

I like the idea of the cookie cutter/punch method, not sure if that would keep it clean, like if you had to twist your punch...

 

Make a pattern of plastic or thin wood and use an X-acto knife. Cut to shape and sand with a piece of fine sandpaper or drywall screen. I never had luck cutting cork on a saw, bandsaw, or anything like them.