To find out if it would be possible to laser-cut the plastic sheet material, I did some tests. Although it was though for the laser to get through the material, it finally gave a decent result.
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noice 
I’d suggest if you can allocate a research centre at a school, try to find a water cutter. while it’s not as fine edged as the laser would be, you avoid the melting problem. High pressure water cuts like a dream and has been very useful for these kind of applications.
@pimvb
Looks awesome, I wonder if Waterjet cutting would work much better than laser since you are using presure instead of heat
Hey @pimvb,
How you doing man?
Great tests. I tried to lasercut plastic sheets too, however, like in our case the strength of the laser was too high melting the plastic around the cuts.
Don’t you think is a matter of tweaking laser settings? Also your sheet looks quite thick, (1cm?), maybe reducing the thickness would also help.
All in all, well done. Looks kickass!
Hi Dianar25,
I don’t know how to build one.
Sounds complicated to me… There are quite some difficult parts that need te be really precise and acurate.
Maybe there’s a fablab that’s willing to help?
Hi Hexahelix, sorry for my super slow response…
I made the plastic sheet material with a tweaked kitchen oven.
Making a simple mold, and keeping it on the right temperature in the oven while pressing material is all you need 
I absolutely can recommend to build one yourself!
Good evening Dave, I did like to be a part of your on going projects which I find very innovative and lucrative. Pls let me know how I can get your product and possibly get trained on this whole innovative project. Looking forward to hearing from you. Here is my number if you don’t mind +353899512197 Toju
I live in the Republic of Ireland and I hope to find someone who is vast in this whole idea
So is it too expensive and/or dificult to build a laser cut machine?
Awesome, I totally like that box!
Would you sell me some “raw” material?
I would like to see what I can do with it.
