Setting up the "Mold"

This is the "strongback" which is shimmed flat and straight. Each CNC cut slot in the strongback will receive a frame which was also CNC cut from the model. That's the frames stacked up on the cart in the middle of the photo.

 Each frame is attached with a cleat.

Then the frames are inserted in the slot and glued and screwed to the cleat. This insures that the CNC cut frames are located within fractions of a millimeter of where they should be.