This style of sunctacher was popular about a decade ago - they were available in malls and other stores. I haven't seen one for sale for several years, so I decided to make my own. This one was a proof-of-concept, to make sure I had the process mastered before making a large piece.
Step 1: Draw your design on a computer. CAM the part
Draw the design with whatever graphics package you are comfortable using. I used VCarve Pro, a package that is capable of simple drawing. It's normally used for CAM (computer aided manufacturing), but it has some drawing tools as well.
I started with an elipse sized appropriately for the center element, and then added several more concentric ellipses around it. I drew a couple of vertical lines just off the center line, about 1/4" apart, then used the trim function to get a bunch of semi-ellipses. The picture shows the process almost done.
Save the file in DXF format.
Since I planned to use the Flow Waterjet to do the cutting, I rendered the cutting paths in their Flowpath software. Since it was a simple design, their AutoPath feature created an acceptable cutting path. I noticed it was not maximally efficient, but it wasn't worth the effort to create all of the paths manually.
I saved the file and then headed over to the water jet to make my cuts.