As promised here are the photos from what I mentioned in yesterdays update. To create a fillet with lasercut sandwiched pieces, the top and bottom layers have to be slightly offset inwards from the outer edge. This is what they start as, with the two thinner pieces sandwiching the larger piece:
Once lasercut and attached to each other, they are covered in filler:
And then finally sanded back to create the fillet and give them an overall more circular appearance:
The larger piece is what attaches the lower moving base to the top, they slot into each part:
Moving onto the new CAM, here it is:
As you can see it still needs to be sanded down and filled, but it has fixed the alignment problem thankfully.