I've made 2 before, as seen in this picture: The problem is, I stuck my finger in the fan and broke the ATI grill (don't ask me what my finger was doing in the fan). So I made a new grill. For lack of a better idea, I made one representing what college I go to. Here's the prototype: On the left you can see a brochure with the actual logo on it for reference. Anyway, here's my question before I redo the grill with higher quality, thinner wood, got any better ideas? I thought about remaking the ATI grill, but I'd rather make something new. (this is the second time I've typed this, first time the power went off right after I finished but before I submitted it, grr)
I think you should put some mesh behind it so that it won't break as easily if hit or like you said broken by fingers getting in the way. if you did that it wouldn't matter what kind of wood you use, so that would give you the best flexibility I think.