C96 Cutaways

[sheepherder]

Originally Posted by Olle

Laser might work?

I've seen on The Science Channel/How It's Made that Lasers and plasma cutters can be dilated to a thin beam and complex shapes cut out of steel plate, but I haven't seen anything thick or variably-thickness/stacked layers like the C96 cut...

Because of the variation in thickness as the Laser or plasma beam goes along, I'm guessing that a constant feed-speed wouldn't work...

And a thin/large diameter grinding/cutting wheel would heat up quickly and leave heat scars...Maybe with water-cooling???

Surface grinding would do the job, but again, you'd lose half the metal...