I am doing calculations on costs for alternatives for manufacturing this children's toy I invented, a puzzle where letters in plastic fit into wood.
I have been using a CNC router to carve subtract the letter shapes from wood and a laser cutter to cut those same shapes in plastic (with some clearance). I have a good idea of the costs involved in manufacturing it myself, hiring someone to supervise the machines, or hiring a service bureau. My understanding of manufacturing at scale is much more limited.
I think it would be possible to get similar and cheaper results by moulding Medium Density Fiber or Perspex. Is that possible? Can you think of other scalable alternatives?