I cheated and bought them off Amazon. They have some that fit the board perfectly and are very good quality. From there I printed icons and then mod-podged them on and stained the tiles to create the various resources and types.
Thanks for the feedback!
So, it feels to me (I may be wrong) like we're thinking of different types of CNC. I'm talking Flat Bed, vertical tooling, to cut a single shape, punch a hole or router out a surface to a given depth. It feels to me like you're thinking of full 3D CNC, which in this application just isn't necessary for the design I've been working on. That said, if I'm mistaken, apologies!
The reason I'm looking at CNC is because I can easily do the Toolpathing myself in Vetric or V-Carve or similar & provide a local company with that & a sheet of Ply & let them at it. Sure, I'll have to pay for that, but the cost should be fairly minimal (I'm in the UK, perhaps its different elsewhere?), but the key thing is that, despite the relatively flexible tolerancing on most CNC beds, what I get out should be sufficiently accurate to ensure that the hexes tessellate sufficiently tightly.
The Hexes mind you are potentially another kettle of fish. I'm looking at a yield per 1220x2400 board of around 2000 hexes. Which is a lot of CNC time. I can mitigate some of that by adjusting my approach to the holes (6mm for a more standard tool so it can just punch right through etc), but the shapes need to be pretty tight (could I make them myself? Sure, but... man. We invented mass production for a reason, I'm gonna use it if I can!). As you've said, there exists the possibility of buying them, but so far I've had no luck sourcing the right thing. I've got close, but the work required is significant (they're not suitable just as they are, though these guys would just about do it, if I could get a few thou...), combined with fairly high costs, makes it a bit non viable.
Alternatively, I do have a few contacts for machining the Hexes & this is something I'm also looking at, those guys love turning out a few thousand of anything!
Anyway, diversion aside, I'm talking local CNC companies here for the benefit of others who don't have the access I do, in my case, I'm going to speak very nicely to my MD & hope they're cool with me buying the materials, doing the programming & pushing the go button. Total cost to me; time + materials = not too shabby.
For others without that, obviously the CNC will cost more, but I don't think it need be prohibitive. Will let you know as I've put feelers out to a few companies I deal with regularly, just to see.
As for the dowel, my plan was always to buy existing & just cut it to length, reckon I need about 4-6 lengths based on my estimates (including saw thickness loss), I'm just not relishing cutting several thousand of the pegs! Can you tell I'm all about automation over here?
But we'll see, I'll get my quotes back from the local CNC firms & Engineering companies & make my call. As long as I can, I'll be using the tools I have access to, but if I can't, I can't!