I have a grid of 3/8" x 2" flat bars that all sit on edge against a curved cylindrical edge. Looks sort of like a storm grate that's been bent into a curve, but really big.

I can use the split command to separate all the bars into their own pieces for the lasercutter. Ideally we could have each piece share a notch and a tab for alignment for the welder.

Right now I've split the parts and used extrusions to add and remove material such that one piece is notched to accept the tab of another. This is seen in pic 1. This approach works, but it's time consuming.

Things are complex as we're dealing with a curve and angled vertical supports.

Is there some sort of tool to make all these notches and tabs more straightforward?

This is all made as one part, with the bodies split out. Should I make them into an assembly and then add some type of part at the assembly level that lets me make notches and tabs?

The 3rd pic is the small one!

Thanks!