I want my cuts to be made with laser precision. Thats why I spent a few hours with the laser cutter today. But talk is cheap. Heres what I got.
I thought about 3D printing, frankencasing, CNCing, or just a good ol' fashioned rotary tool. I went with the laser. Lasers can cut squarer corners and shorter gaps that a CNC router, substantially more precise cuts than a dremel, and a smoother and more accurate edge than a consumer 3D printer. A cut can take as little as 40 seconds, so several tweaks can be made in succession in no time at all. Be warned: lasering ABS emits cyanide gas, and is not a good idea unless your laser has an advanced ventilation system. I received specific permission to do so from the department at my university.
The case is a Polycase SL 57. I have always disliked boxy polycase portables, but the SL57 stole my heart. Its rectangular, but small enough to not feel boxy. The edges are rounded. It feels so nice in the hands, and so nice in the pocket. I saw @Gman
use it as a controller/av adapter for a N64 in a video, and I immediately paused the video and tracked him down to give me some info on it. He made a gamecube out of it similar to mine, which has served as inspiration.
So tiny. So comfy. So rugged.
I designed the cut and ran the machine myself, so I should still be within the rules. It took several rough drafts on acrylic before I finalized my design and threw 3 SL57's on the bed. Every draft I made several changes, such as moving holes, adding holes, and rescaling cuts by as little as 1%. The results were worth it. The sensor bar and power indicator LEDs are friction fit, while the first party gamecube buttons and tacts are a perfect fit, and can slide without wiggling.
Anyone who says they got it right the first time is either lying, or has low standards.
More to come.