Step 3: Mockup
My plan was to laminate six layers of cardboard together for each panel. 40 panels x 6 layers = 240 pieces! That's a heck of a lot of cardboard. Luckily there is almost always someone who has just moved to town and is looking to get rid of their moving boxes for free on craigslist. I snagged a batch to make my prototype pieces.
I cut enough pieces to lay out a 3 x 4 grid on the floor. This would let me see if the idea was headed in the right direction. I'd be able to tell if I liked the star pattern made by the negative space or if should reconsider the dominoes. After spending the evening cutting out cardboard pieces with my CNC machine I came to two conclusions:
First, there was no way I was going to have the time / patience to cut out 240 pieces.
Second, the recycled cardboard looked kind of crappy and the design was cool enough to deserve a better material.
1/4" plywood perhaps?