[asid61]

Well we just made a bunch of gussets today. This time went a bit faster than last time.
Essentially we set up the table saw with a metal-cutting blade, cut the gussets as squares, then just clamped them together and stuck them on the mill to do the holes. Took us about 2 hours total including setup to do 16 large gussets with 3 people (although it really only takes 2). I think we'll stick with this method for now, and switch to printing and cutting manually if there's a problem. It scales up in quantity really nicely.