The new case for my Geiger Counter kit started with a CAD drawing of the top and bottom case panels, as shown above.

I am very fortunate to have access to a ULS laser cutter at ATX Hackerspace, which is perfect for cutting 1/8″ acrylic and has a 32×18″ bed.

I made a few quick prototypes with some scrap acrylic and hardware I had in the lab.  The version shown here is the first iteration, which had taller standoffs and no battery cutout.

Once I was satisfied with the design, I created an array of panels.  18 cases (36 individual panels) fit on a 32×18″ sheet of acrylic, which just fits in the bed of the laser cutter.

The laser cuts out each panel in the array.

This is what the sheet looks like when the laser is done.

Mmm, freshly cut cases!

Add a few screws and standoffs and this is the result:

A beautiful clear acrylic case for my Geiger Counter kit!