I last built something of this style back in 2003, and it all sort of foundered in a heap of badly written matlab code. It's been a back-burner project to rewrite it in python, and investigate using a computer guided cutter to cut them out. Linda is enthusiastic about making her Silhouette cutter do it, but I started on one by hand as a proof of concept for my code. Here's where I'm leaving off tonight.