After some help with the amazing TA Essie, the SolidWorks difficulties were solved! We had more luck with another of the various versions of the "trim entities" sketching tool, and managed to finally remove the last few remnants of the guiding ellipse by greatly magnifying the view to make sure the correct tiny portions of ellipse were deleted. Then I printed the bottle opener on the laser cutter! I used 3/16" Delrin for the part, as it was thick enough to be sturdy but thin enough to fit easily under the bottle cap. I ran to open the first bottle I could find immediately after the laser cutter finished.
Ahhhh...sweet success!
Unfortunately, we had some difficulties with inaccurate laser cutter sizing, so we were only able to get an approximate size; while the bottle opener works quite well to remove a cap, the part is a tiny bit too large for the perfect grip. While it is by no means uncomfortable, and for someone with larger hands this size would be ideal, the part does not exactly fit my hand in the way of my foamcore model. But despite this minor issue, the bottle opener works fantastically, easily opening bottle after bottle!
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