I used Autodesk 123D Make to split my .stl files into layers. I had chosen the thinnest felt to make the most of the contours. I used a micrometer to check and it was indeed, 1.2mm. The fibrous mature of it means that the layers don’t sit really close to each other so I knew that I wouldn’t need as many layers to build it.
Above: The 123D interface.
Cutting the felt was straightforward with the laser. The edges got burn a little bit. I thought this would happen. It’s partly why I chose a mid to dark shade. I think it works okay. It helps define the contours and is subtle enough against the gray.
I put all the pieces for each module in sepearate bags but it did look like an impossible puzzle!
Above: The resulting layers are output as an .eps file which can be sent straight to the laser cutter.