Step 1 router a bunch of rib blanks all at once.
Step 2 debur edges.
Step 3 Press rib blank and make round flanges.
Step 4 Put blank with round flanges in a mdf assembly
Step 5 Rubber mallet $7
Step 6 Add scallops while slowly being formed


There are many ways of straightening potato chip rib once flanges are hammered.

This is my way of doing it:
Step 7 Place rib in my flange finish tool
Step 8 Press down- Clamp Flange edges with set screws.
Step 9 Use wooden dowel to force flutes into scalloped out mdf form
Step 10 Still have to over bend flange because of aluminum spring back.