Thanks, guys, for the suggestions!

The machine is intended for routing parts of plywood. That means
cutting through the material. So that is why I do not think that
having the grid-style grooves on the top surface is the best idea.
Besides, it is expected that mostly it will cut the same layout of
parts many times - lots of repetitive work.

My intended solution is:
1) basic frame, which will support the table - working envelope is 2500*1500 mm;
2) bottom plate (most probably - plywood) - with vacuum supply holes
and a grid of grooves to distribute the vacuum. I intend to split the
envelope in several sections by creating several grids of grooves that
are not connected and each having one or more vacuum supply holes;
3) top plate (plywood or steal or some other metal) - with ~2 mm holes
that are placed to match the grid on the bottom plate;
4) spoilboard (very dense cardboard or some similar cheap material) -
with drilled holes to match the holes of the top plate except for
those holes that happen to be right under the path of tool. Any
changes in layout will require new spoilboard, but that is acceptable.

Custom parts will have to be created by leaving thin uncut layer on
the bottom of material. But it seems to me that many are doing it this
way.

That is how I think I could achieve cost-effective solution - avoiding
any leaks would allow for a not-very-powerful vacuum pump.

Viesturs

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