The baskets that I have made and shown here are made up of 9 layers of 1/4" solid wood. Top/bottom are stack cut by themselves. Then I cut a stack of 3 and a stack of 4. I use #5 Pegas mgt blades and take my time. So, to answer your question, I guess 1 inch would be the max for me. I've not tried BB plywood yet so I can't comment on that. I've had good luck with poplar, red oak, maple and walnut. It might also depend on what saw you are using. My first attempt was on my Dewalt. Since then I've used my Hawk and my Ex21. All good.