I'm trying to make some scale models from styrene and having some difficulties joining the edges.
For 90 degree corners I'm engraving the fold lines with a 90 degree V point tool "almost through" and then folding along the line and using some poly cement to make the joint.
The problem is where I have a corner which isn't 90 degrees, ideally a 5 axis machine would be able to cut the exact angle on the edge of the sheets. I only have a 3 axis machine and wanted to find something in between a basic 2.5D solution and having to model each sheet in 3d and then machining the parts out with the requires angles on the sheet edges.
I hope this illustration helps to explain what I'm refering to:
The image shows the resultant gap when the sheet is bent to angles less that 90 degrees.
http://img152.imageshack.us/img152/3767/image1sr1.jpg