I went back to the drawing board with the goal to accomplish 2 things.
1. Make the imagiplanks in a way that will eliminate any of the quality issuse previously experienced.
2. Make the manufacturing simpler to keep our price down
The plank design went from the hourglass shape to a straight shape. The artist in me had a hard time with this but the straight design is more versatile and does not require a costly CNC router to make it.
I also found a solution to attaching the staves to the planks that does not require any sharp screws, nails or staples and doesn’t require glue.