After analyzing many libraries of frame captures and reference photos of the HAL9000 from 2001 and 2010, I decided on a height scale for the faceplate.
Once I had a height measurement, all the other pieces were scaled accordingly and drawn out in my CAD software. To do this properly I decided to create vectors for each individual height layer. This necessitated vector files for: 1.) The baseplate (etched with the positions of the upper layers) 2.) The gridplate 3.) the decal plate 4.) the lens rings
Here's what this looked like directly off my laser cutter:
And here's a test fit:
Now I needed to create the body of HAL. I did this by laminating poplar with the faceplate.
Once the lamination was solid and the edges routed smooth, we machined the inset hole for the eyepiece:
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