The game has 38 hex tiles; 53 if you include the 5/6 player expansion.
Rolling out the poly clay for all those isn't too bad, but trying to cut them out could get ugly and time consuming.
Another fellow who made 3D hexes used a board with thickness guides to roll out the poly clay. Natch! That's the easy part. Some poly clay websites have suggested a pasta roller for quickly and easily rolling out clay in even thicknesses. I like making homemade pasta, and the machine would make rolling out the clay to an even thickness easy; it's an option I'll have to keep in mind as it gives me an excuse to buy a piece of kitchen equipment I've wanted for a while. I'd just have to make sure to clean REALLY well after I'm done using it for this project.
That same fellow I mentioned used an existing hex from the Settlers of Catan game set as a guide for cutting his hexes. That doesn't work so well for me. I don't already own the game; If I did, I probably wouldn't be going to the trouble of making my own.
So that got me to thinking about using a hex shaped cookie cutter to cut the hex tiles. I think that's likely to be my best option. I can get hex shaped cookie cutters online from Golda's Kitchen.
I'm sure if I look around some local home furnishings shops I'll find some locally and save myself the shipping costs.
I need only check their geometric trueness, and cut carefully, and it could save me a whole lot of time in comparison to using some other kind of jig/guide setup. I could easily cut several hexes at a time; probably faster than cutting a single hex with a hobby knife and ruler. I'm also more likely to have straighter (vetically) sides by using a cookie cutter.
I guess I have some shopping to do.
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