I've had this idea bouncing through my head for a long while now. Just don't have the tools to try it. I'm wondering how well it would work to print on stickers and attach that to wooden blocks cut to size. Maybe even using 1/4" basing instead of foamcore. I really wish I had some woodworking tools to try this out. Of course, this would work best on the chunky sets...

My thought is that wood still expands and contracts an awful lot. The fancy name plate and plaques I got over 11 years ago can visibly change size, which causes the metal parts to bow out away from the wood one time and then appear to be snug against the wood the next. I think wood basing could have the same sort of problem. On the other hand, if you wanted to work with plastic sheet, it might be more permanent. The idea of printing on stickers was something I was looking at some time ago to make round base stickers for my pirates and some other figures that would do most of their fighting indoors or on wooden decking, and I printed the Maiden or the Pubs & Inns floor on 1" circles, then carefully cut slits to work them around the feet of the figures. This also makes very short work of basing, you dont have to flock or texture the base, and they blend in with the wooden floors. Plastic has little to no expansion and contraction, unless you leave them in extreme temperature changes.

Plywood might work since they tend to rotate the grain of the wood by 90° for each ply when making it which gives it more stability. You can cut out a lot of tiles from a full sheet.

MDF is the way to go. It is also the material a number of terrain companies use when making slot together pieces - with a CNC machine.

This here show such a company - I feel that it's far enough from Cardstock that it would be safe to post.

End result is that MDF is great but make sure you ware a breathing mask when cutting and sanding.

Yes this would be a great project and would stand up very nicely.

Lord Abaddon of Wormwood