With the CAD done, we moved on to manufacturing. We started by laser cutting the wooden components. The design was built around 5 mm plywood for almost everything. We used:

• Three 80 cm × 60 cm sheets (5 mm plywood)
• One 50 cm × 50 cm sheet (3 mm plywood)

Here is the cutting layout:

5mm plywood	5mm plywood
3mm plywood	5mm plywood

And here is the cutting process:

We did run into an issue later with the curved rail plywood gear: the teeth kept snapping off. To fix it, we swapped to 6 mm acrylic instead.