We began cutting out Nora and Torvald. The material is half inch thick European Birch plywood (9 ply). The profiles were made in Rhino, nested with the Mosaix plug-in, and sent to Mastercam as IGES files. The parts were CNC routed (thanks Josh Bard) almost the entire way through the material and then manually separated from the sheet using a trim router and a laminate cutting bit – this was to prevent the smaller parts flying off and screwing anything up. The last image above is a dry fit after a light sanding.