From Trammell Hudson's Projects
I used my maze generator to produce a SVG of a 32x32 maze, then cut a cardboard prototype on the NYCR laser cutter.
For the first prototype I manually cut the pieces to be about the same size with an exacto and used a 45-degree cut. This made it easier to assemble; it took me about an hour to piece it together, which is roughly the difficulty I expected for this size, although scaling it to 64x64 will likely make it significantly more challenging.
I cut a second one with straight pieces and haven't successfully put it together yet.