linwiz wrote:This is where I got the idea from, and his method seems to work great. I would need to have a different mold than the one he used, one that creates a hollow box the pi can fit into and one to make the lid.
http://www.instructables.com/id/How-To- ... -Easy-Way/
That's pretty cool. Should be able to machine that into something nice. I've done some vacuum forming of sheet plastics. You can do this in your home workshop too. Here's a video of a homemade machine and how to make a part:
I watched several of these videos, most who tried this had varying degrees of success. When we did this we used smaller holes and many more of them than shown in this video, and we drilled holes in the base to draw air where we needed it to form the part nicely. We also drilled holes in the mold itself if needed to prevent warps and wrinkles and to provide finer detail in the part. Some of those were very tiny, maybe 1/32". And, of course, you need to build your mold in a way that the part doesn't lock itself around it.
One can make some pretty nice custom cases for a Pi using this method.