I happened upon a blog posting by some guy who calls himself Waco Joe. He figured out a way to create terrain tiles for gaming by using cake dummies. The blog entry in question that caught my eye can be found at the following link:
http://joxash.org/blog/?m=201008
The tool that he used he called a Proxon foam cutter. However, I think that the actual item is technically called a Proxxon Hotwire Cutter Thermocut, and if I managed to track down the right beast, then here's a link to the actual product:
http://www.proxxontools.com/store/pc/viewPrd.asp?idproduct=85&idcategory=0
The company that Joe bought the cake dummies from is located at the following link:
http://www.dallas-foam.com/store/
I am more interested in 3 inch hexes than in 4 inch hexes, but even still, Joe's method may yet be the best method that I have come across, as far as being cost effective over the long term, while simultaneously yielding consistent results with the actual hexes are concerned.
