Wood CNC's..

If you are going to go to the trouble, why not machine a foil out of a block of laminated wood/composite. I don't remember anyone trying that.

Build your block out of wood or foam laminated with fiberglass, carbon, Kevlar, foam, aluminum... You could leave appropriate volumes hollow and except for your reference points, the finish could be sloppy.

Machine out the foil then machine out the skin(wood, carbon prepreg...) and glue them together

Or use a reinforced paper for the skin. Print it out on a large printer with little cutouts to make it lay flat. You could print whatever graphics you like. You could have a foil with your face on

I don't think this has been tried with a foil. I have heard of similar methods used for architectural pieces or high price furniture. You could be the first and lead the way if it shows promise.