Didn't we see a post on here a bit ago of a guy punching out picks or plectrums as he called them? Could you slice and punch instead of shape and slice?
One MORE idea:
A gorton Pantograph.
You can make one master and then by varying the arms, cut many different sizes.
It can't cut too deep (the motor is made for a tiny engraving bit), but the results are stunning.
Here's one on Ebay
They often go for very little because they are outdated (or, so many people think!)
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