Once you have data, you can use various processes to make large type. When FontShop released our new FF Real, I took the opportunity and had one weight in one size cut from maple wood. I took the font data and surrounded the outlines with a thin line. That instructed the CNC machine to cut the body of the letter just 3 units (on a 1000-unit system) away from the extreme points of the character shape.

Buchstaben Gemacht
We’ve tried it all: plexi, maple, pear, resin, magnesium, polymer, formica. CNC milling, 3D-printing, pantograph cutting, etched metal, vacuum-forming.
Real Anweisung
Instructions for CNC milling.
Real Tisch
This is what new wood type looks like.
Real Korrex
FF Real as wood type, 16 cicero, in the Korrex proof press.