

Yes, regarding the mesh. I was wondering if a flexible mesh might be better. Toynbee tiles seem to become illegible mostly because individual pieces shift over time and make them look more of a jumble, this becomes more pronounced as the individual pieces become smaller. I was thinking more fiberglass, too, but even burlap would be fine probably.
A good flexible adhesive on the back of the pieces then pressed firmly into the fiberglass/cloth and weighted until set up.
One thing to consider is that the asphalt crack filler needs to be pressed into and around the pieces, serving a role similar to grout in tile. So the order of operations would be important. That’s more of an assembly issue, I guess.
There are numerous open source tile mosaic softwares out there that will generate the tiling, including the needed gaps for ‘grout’.
And Armstrong Flooring makes VCT in a huge array of colors. A source for vinyl tile of specific colors
Super fun, I am going to talk with my local folks and find a good location for a small test of these ideas. Such fun, thanks for engaging
3D printing can be cost effective for small production runs too. There are large format printers both FDM and SLA with print quality, large bed size and speed more than sufficient.
Injection molding is only cheap when print runs are huge. In a rapidly developing space like drone warfare, a lot of plastic parts get changed frequently enough that injection molding becomes cost prohibitive, due to small production runs between design changes.
Take the example of a propeller vs a custom bracket to hold a new type of clip for ammo.
Propellers can be standardized according to motor, frame geometry, and power source parameters, so they can be mass produced with injection molding by the ton.
A bracket needed to test out a new configuration may only be made in runs of a few hundred before some other update changes things again.
All this is to say that drone warfare is logistically an insanely complex supply chain to manage.
3D printing will have a role in drones that see combat until the day the designs are completely perfect and never need to be changed again. Then the economy of scales can overcome the high setup costs of building an injection mold.
And the Pentagon will stockpile them by the billions to give SkyNet something to work with later. yay.