I converted and modified some 3d printable tiles so I could make them using my CO2 laser cutter.
the small tiles are 3x3 and the big ones are double that 6x6 they I made them that size for a 40k board im building, but they can be resized easily enough.
Cut the details on 1mm cardboard, then glue them to an MDF base board either cut with a laser, or cut manually.
If you cut the base with the laser you can engrave the grid to help line everything up as you glue it.
There is also a sample file showing what a big layout might look like... and the first sample i did to test how it would all work (I edited the detail parts after that test)
BaseBoard_300x300.svg | 3.5KB | |
BaseBoard_600x600.svg | 11.0KB | |
Details_1mmCard.svg | 149.2KB | |
SampleLayout.svg | 1.4MB |