I’ve been working on a Digital Fabrication Technique for building precise 3D-faceted forms. I ended up making an armature, which is close to a good solution, but still has too much play in the joints.
One of the other resident artists at Autodesk, suggested a solution where I make wooden squares to solidify the joints in the armature. I cut out a variety of squares, each with a slightly different width+height, to account for the kerf of the laser-cutter. I also laser-etched them with their measurements.You can see here where I cut out a groove in the bottom of the armature, 1/8″ deep. The square fits nicely in there. I found that 25/1000″ seems to be the right amount of compensation.
This is what it looks like before I put the last panel on.
It looks just like the model!