I would'nt worry too much about how it all works
Fine, it sometimes leaves a little bit ot 'dross' on the underside, but a quick rub over with a file and it just falls offHow does it perform on aluminium?
I could do it for you, one tip if you have to create a shape is to print it out 1:1 and then cut the shape out to see if it fitsIf possible, would you be able to run some stuff out of a possibly A3 size maybe smaller piece off 2mm ali?
I have had a go with the autocad and I am pretty certain i have the design correct although I would need to duplicate the shape to fill the material.
Finish wouldn't have to be to brilliant as I will be rounding the edges.
At least 10mm on that partHow much of a gap do they need between pieces?