Thanks Burrman - I had crossed past Lamina years ago but didnt really have the way to cut those shapes outside of laser - I have just setup a CNC Plasma really economical setup single phase and just with an air compressor the cut quality is amazing. Ill have a play with lamina I have some 1mm aluminium should be soft enough to get it to bend into non planar shapes.
Here is a trial shape in 3mm Mild Steel 20mm Slot 3mm Tabs just like bending cardboard. I model the shapes with unthickened surfaces and so far the material thickness has really not effected the shape coming together I guess that maybe a problem in higher gauge materials.