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solid body to assembly of flat surfaces?

Question asked by Guillem Cabo on Dec 5, 2016

I have to make the plans for assembly some letters in 3d form laser cutted 3mm MDF

I have obtained the outline of the letters and i have extruded the surface to get the 3d model. After that i have obtained the dxf of each face and made the modifications to have a nice fit considering the thickness of the material. I think that it isn't the best way to do it but i don't know any alternative.

I have taken a look of the metal toolbox but i have no experience with it. The idea is get something like this but for the letters, allowing a push fit between faces.

Which is the best way in your opinion? Thank you in advance.