My current exploits in the hobby have been centred around making an old school D&D style dungeon game board and its been quite an interesting adventure. I have tried all manner of ways of making flagstone floors, from printed and etched, hydrostone, polyfilla, cork, stamped and so forth.
Tonight I cast my first resin flagstone sheet directly onto 3mm MDF backing, and bingo. Exactly what I was looking for. Resin casting is usually not cheap, but the amount you need for a flagstone sheet is tiny- and the silicone mould I made will survive long enough to make at least a seven level dungeon- so really its only about half a bottle of pinkysil and a box kit of resin.
The result is lightweight and sturdy, and it would take me an afternoon to cast up everything I need to make a decent nights gaming table. Nice.
My floorplan uses a 3cmx3cm square size, rather than the traditional inch you find with dungeon tiles, as some players have warmachine bases on their minis, and the extra room means models don't rub up against each other.
A couple of discoveries during the journey worth sharing- polyfilla woodflex is absolutely brilliant for making wargames scenery- it does not crack or flake, and gives a rocky texture that wont scratch paint of minis. Two thumbs up. The second is that you can harden Balsa wood- which is news to me, and totally opens up a whole new modelling route for me. Simply paint on superglue, or (or slow set resin) and voila. Clumbsy, impatient modellers like me can make stuff that doesn't crumble!
Now, to write a set of dungeon rules to go with my new toy!