Just hit upon a good material for plazma cutting patterns -- PERGO laminate flooring.
Use with the hard laminate surface up. Cut to shape with a fine-tooth band or jig saw. Flash zone of the cut erodes and undercuts the partical board substrait, but the laminate surface remains true after many cuts.
Use with the hard laminate surface up. Cut to shape with a fine-tooth band or jig saw. Flash zone of the cut erodes and undercuts the partical board substrait, but the laminate surface remains true after many cuts.

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