Water jet cut 4" stacks of cardboard. Yielded 98% of 1280 parts for 8 chairs.
0.60" x 1.6" hole for press fit 1.5 x 0.25 lapped cross bracing. Worst case distortion at bottom of the stack. Too great a feed rate.
Mill to a specific depth, work hardened with one bend and one bend only. Get it right the first time or *snap*.... nice fast detail.
No fasteners. Press fit. Overlapping cross bracing.
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