If you don't have access to a CNC Router (SHOPBOT!) and you want to make multiples of the same shape, you can do it the old school way and get the same results. It just might take a little bit longer, but the outcome is the same.
(If i win the ShopBot i'll make plenty of these and give them to instructables, they are very comfy!!)
Things you'll need:
- template shape (existing or made from scratch)
- Router table/Hand Router
- Flush Trim Router bit
- scrap plywood
- double stick tape/finish nailer
Step 1: Make Your Template
Make a template.
Use material that is easy to smooth over (MDF) because flush trim bits pick up on any inconsistency in your template. Those inconsistencies translate to the duplicate pieces you create. I used a piece of CDX ply because it was all I had around although this is not an ideal material in that it is hard to get a clean edge.