I don't know anything about the walnut shell prototyping, but I may be
able to help make your large parts. I have been using a five axis water
jet cutter to cut sheet material and manually stack the layers.
The water jet can cut most materials, even 20mm thick steel. To date I
have only used foam sheets because it is so cheap, but I can use just
about anything you want.
You can see a life size dolphin model I made on my web page at:
Department of Mechanical Engineering
The University of Queensland
Brisbane QLD 4072
Ph +61 7 3365 4179
Home +61 7 3371 0990
Facsimile +61 7 3365 4799
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