Cut and Etch the Design
Use a rotary tool to etch the design. You can use a razor blade or chisel, but a rotary tool is a quicker and more effective. Start by etching the superficial (skin) layer first (which is indicated by red in our design). Pass the rotary tool lightly over this color removing about a 1/4 inch or just the outer layer of the pumpkin's skin.
Next, apply more pressure and etch the deeper layer (which in our design is indicated by green). The deeper layer should only go about a 1/2 inch deep. Take your time and etch this layer in stages so you don’t run the risk of breaking through the pumpkin. Even though these two layers look very similar, when the pumpkin is lit at night the deeper depths will glow more brightly than the others.
The third level, indicated with the color blue, will be the sections that get cut all the way through. Use a drill or any long, sharp tool to cut holes for the eyes, nostrils and detailing around the face.