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No problem @hairybrains, always glad to help, and I think your choice to stick with 3d printing is a clever one.
Just to make it straight, however, 1mm styrene is not much of a problem. Sure the machine won’t cut it through, but it doesn’t need to. I mean, when I cut plasticard with a knife and ruler I also only score it and then break it along the line.
The other way is to use thinner material and cut multiple layers out of it, then stack them one over another.
All in all, as it was already said, 3d printer will actually give you much more options for less hassle.
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