Normally you would want adequate spacing, but due to me planning out not only the direction I am going to cut something, but the order as well, it allows me to cut them out one by one without the overlap. Also I have a fairly small knife that I keep sharp, maging it easier to cut with little room between. As for shared lines, I generally try to avoid it as much as possible. Plus I try to conserve as much foam as possible to not waist as much
For example, on a piece like this I would cut out the verticle cut first (1) to cut out and remove that piece, and then once it is removed and out if the way, I will make the horizontal cut (2) into that empty space
I always try to cram as many pieces as I can on a sheet of foam as well. Don't like to waste foam. Saves money. lol.
I don't have it as tight as you do because I am using a larger utility knife so... more chance of slipping up and cutting into something that I don't want cut.
Pretty much the same deal with the thighs, except I made the hard case, which is more function that form. It specifically is where I'm going to hold my phone, so here is some picture dump. Ohh and I can sit down comfortably. I think that covers My bases.
Okay so just a bit of an update. I am going to be taking a break on this for a couple weeks, next week I have a big final, and there is no way I was going to get the project done to take it home. Once I'm back from my trip home, than I'll be picking up where I left off. One thing I am working in right now, is the custom paint on the knife, so once that's done, I'll be putting it up.