All of our boards (except the fitted boards, of course) are made of one piece of wood. All are made individually, piece by piece. There are no laser cutters, no duplicating machines in our little workshop.
First, together, Tom and I design clear patterns. Next Tom looks at each rough board and places the pattern on each to show off the best grain. This process is more time-consuming and uses more wood and brain cells than simply getting as many pieces as possible out of each rough board, but we like the end product better. It makes every piece truly one-of-a-kind. After patterns are transferred to the rough boards, Tom cuts everything out on the band-saw.