I've heard of a process of producing sheets of wax for foundation on a
   small scale:
    a smooth wooden board is made of the intended sheet size.
   the board is dipped in water first, then into a a tub of melted wax.
   as it is witdrawn from the wax, a layer of wax solidifies on it.
   re-dipping can increase the thickness, re-dipping from the opposite end
   can even out the thickness.
 
   When the wax on the board is acceptable, the edges are scraped,   and
   the sheets of wax removed from the board (one on each side).
 
   The sheets can then be rolled through rollers to imprint the hexagonal
   cell bases.
 
   I understand a lot of foundation of this type has been made.
   good luck
 
 
   Kerry Clark, Apiculture Specialist
   B.C. Ministry of Agriculture
   1201 103 Ave
   Dawson Creek B.C.
        V1G 4J2  CANADA          Tel (604) 784-2225     fax (604) 784-2299
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