For a music room we wanted to install acoustic foam in an appealing form. We liked a few hexagons made of foam covered with felt, but we thought that the exact assembly could be a challenge.
That's why we designed this template, which has a three-part plug-in system and can be extended at will. The exact assembly is thus greatly simplified and the elements could be aligned exactly at an angle.
Our foam-hexagons have the following dimensions:
Diameter 440mm, edge length 220mm, thickness 50mm.
The stencil surrounds them with +60mm, so the resulting hexagon has an outer diameter of 500mm, thickness is 30mm plus grip holes so you can work with it and get the stencil out between the foam elements.
I bought the hexagon here: https://frankenschaum.de/navi.php?qs=hexagon.
Although this template may not be suitable for your use, it may be an inspiration for your purposes.
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The author marked this model as their own original creation. Imported from Thingiverse.