Thanks boys for putting your thinking caps on.
Graham, I'm happy with making the sheets...I've done loads, but not in such a tiny scale - 3" corrugations equates to roughly 1/2 of a mm - I don't know, but I suspect plastic rod that size would be hard to find and then difficult to glue in a straight line and keep the contours free of glue. This dilemma will apply to anything so small glued together, so care will be needed. As you know, with the larger scale corrugation making 'machine' this problem doesn't occur.
Tony, excellent suggestion, but I think the comb teeth might be too big....We are talking mega diddy here!!
However your idea has sparked summat mucker. Hows this....
Instead of a couple of combs, substitute these for either two sets of Andy's panel pins or sewing needles glued as you would the cocktail sticks, then adopt your vice method. This might, just might work. The problem is the tiny size.
All great suggestions and thanks for offering up all your ideas.....Time to try them all, me thinks!
Cheers,
Ron