Re: Wall Panel Relief
I do a lot of similar stuff but on a much smaller, and in my opinion, achievable scale on my machine, and I can agree with everyone else the amount of hours it takes to machine stuff like that is mind boggling, add self built or hobby grade machine into the mix and the times will likely blow further out in most cases. And the better the finish the smaller the routing stepover or overlap required, as well as the smaller the bits required, all greatly increasing the machining times.
Aside from the mold making suggestion which would be far, far better, High Density Polyurethane is an absolute dream to machine if you do need to go the routing option. But as others have suggested, the thinner pieces will still be an issue regardless and the HDP may need to be bonded to a sheet of thin ply before machining.
Here in OZ a 2400mm x 1200mm x 20mm HDP sheet tends to run anywhere from $200-$400 depending on supply, so it's incredibly expensive but you can make it go a long way.
cheers, Ian
It's rumoured that everytime someone buys a TB6560 based board, an engineer cries!