Lego Jigsaw, prototype I

First pass at routing some prototype pieces of my proposed system.

Successes:

• It fits together!


• It's (reasonably) material efficient - the good majority of the surface area of the 2'x4' blank was used.


• It does seem to be pretty flexible in terms of application and very initial tests indicate it's fairly strong.


Failures so far:

• Need plywood without veneer, or I need a slightly sharper and deeper cutting job, so as to not have to shred and destroy it cleaning the cuts up.


• I messed up a bit on the placement of the passthru slots, I think


• I was aiming at 2'x1' pieces to fill up the 2'x4' blank, but given endmill overlap on the cuts I had to scale them down, resulting in some material inefficiency.

Pile of most of the veneer that I had to break off.