Hi all-

 

I'd like to make a few custom parts using off-the-shelf switches such as rockers and pushbuttons.

 

I see that there are typically opening dimensions, and the switches themselves have "arms" that expand to lock them in place.

 

However, I'm not sure about a few things:

 

1) What thickness should this plastic be?

 

2) What type of plastic should I use so that I can glue it?

2a) One reason for gluing is also to build ribs into the structure to increase rigidity

 

3) Where to buy? Amazon? Specialty plastics?

 

4) (bonus question!!) I'd love to be able to lay this out and print it so all the openings are perfect... I know that ain't gonna happen, so what's the best way to cut this material? I'd like to avoid having to make 60 scores with an x-acto blade...

 

Thanks!

Andrew

Anyone?

One thing I've done in the past was use jigsaw blades and drill bits designed for plastic.  They worked well for the project I was doing.  I got them from Delvie's Plastics, which has a bunch of plastic options, but I only bought there as they are local to me.  I've done some looking into using ABS for some custom panels, but for the reason that I was just more worried about cracking the acrylic over ABS for an instrument panel.
Both ABS and Acrylic could be black on white and then engraved to add labels (like here for ABS).  There is also 2 tone acrylic available out there.   Here's one place I found that can cut it, and has the 2 tone acrylic, (there are of course many others...) but that page also has good info on several types of plastics.

 

When I do something next I'll probably go for the black on neutral (so it can be backlit) ABS, and have it all laser cut so I don't have to do anything additional.  It just takes additional planning.  Thickness will come down to cost, but I'd like 1/4" if possible, down to 1/8" minimum as there is still lots of flex there.

 

Hopefully some of that info helps.  There is ton's of stuff out there.

Hopefully some of that info helps.  There is ton's of stuff out there.

 

Thanks! Will look into it.

Hi all-

 

I'd like to make a few custom parts using off-the-shelf switches such as rockers and pushbuttons.

 

I see that there are typically opening dimensions, and the switches themselves have "arms" that expand to lock them in place.

 

However, I'm not sure about a few things:

 

1) What thickness should this plastic be?

 

2) What type of plastic should I use so that I can glue it?

2a) One reason for gluing is also to build ribs into the structure to increase rigidity

 

3) Where to buy? Amazon? Specialty plastics?

 

4) (bonus question!!) I'd love to be able to lay this out and print it so all the openings are perfect... I know that ain't gonna happen, so what's the best way to cut this material? I'd like to avoid having to make 60 scores with an x-acto blade...

 

Thanks!

Andrew

Sorry, for the really late answer! I was going to recommend 2mm to 2.5mm regular acrylic (plexiglass) panels. You should be able to get them in any hardware store and they're relatively cheap. Before I offer any more advice (which may be unneeded), what solution did you opt for?

 

Cheers,