The work was tedious at least, the model didn't look very good and it took forever to make.
I reached the conclusion I need a CNC machine to do the complex shapes I want.
It needs to be able to cut foam in 3D, making complex shapes. For this I think a loop of nichrome wire of 1/4 -1/2 inch diameter would do nicely. To ensure rigidity of the loop some thicker gauge wire should be used.
I would like to use it also for cutting/engraving aluminum, wood, plexiglass.
Size: As big as possible. 4 x 3 x 3 ft would be nice.