I have designed a board game where the board is a grid of 145 holes. The holes are a specific shape, and they are aligned with each other very precisely in a beehive grid pattern. I am thinking of creating a Shapeways cutting tool which would be as large as the board, consisting of a separate hole cutting shape for each hole on the board. I want all this to be a single physical object, so that the holes will be positioned accurately. This tool would be mounted on some plywood. The board, which might be sinter or foam core, would be mounted on another plywood frame. The two frames would push together, perhaps using a large vise grip or similar arrangement, to cut out the holes. I don't want the holes to go all the way through the foam core. I can dig out the foam from each hole once the vertical walls have been cut. Would a steel Shapeways design hold a cutting edge for such a purpose? How sharp could the cutting edges be? What's the sharpest angle allowed for a cutting edge? How strong should the framework that holds all 145 hole cutters together as a single unit be? I would imagine you would have to build a strong outer shell to keep this thing from getting bent during shipping. Has anyone done anything like this before? Thanks!