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.
Here’s a video of the laser cutter in action – the audio is a bit loud, so you might want to turn down your speakers.
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!