On a related note...
I am in the process of building a rolling cabinet to store my poker gear. Think of it as a mutli drawer "mechanics toolbox", only made of wood capable od storing 4-5k chips as well as cards, buttons, poker genie etc. I am at the point of needing to fabricate chips trays with storage of 100+ chips per row 10-12 rows wide.
I was thinking about doing the router method as well until I noticed some scrap Cove Molding in my shop. It has a a simple concave curve the exact size and shape of a chip

(see profile below). By putting two of these edge to edge they form the perfect trough to hold chips. You can adjust them further apart if needed to compensate for different diameters. Trim the flat edge to reduce the width between rows. They can be painted, stained or covered with velvet if thats your desire.
I figure, why re-invent the wheel? These will work perfect for my application and I don't need to worry about goofing up any material machining them myself (or locating the (probably expensive bit(s) I need).
I am going to start a new thread later tonight with actual pics of my process.
Not the best pic but gives you the jist of what I am talking about.
