Making Casings for Prototype Electronic Devices?

kiddailey asks: "I'm working on a project for self-enrichment that involves creating a working prototype of an electronic device. I've made a model of the basic shape of the device out of Sculpey ^(tm) and want to use it as a mold to make the actual plastic housing that I can then insert the electronics into. Has anyone done something like this before? Is there any way to achieve this without a significant R&D buget?"

Comments

sculpey/fimo clay

[digitalmuse]

well, if you're really going for a simple/lo-tek/ghetto solution, check out sculpey polymer modeling compound. It's easy to find, simple to work with, non-toxic, and once you bake it, you're all set. The only immediate draw-backs are the fact that you're going to have to pre-form at least a starting hole for any screw-mounts (unless you want to get fancy and use pre-tapped cores...) and your project may end up looking like a bad craft project. Then again, I have to suggest it for simple DIY factor and simplicity. Shape, trim, bake @ 250, done!.
But then again that's just my 2 cents and I already use it for some craft projects, so YMMV. I do have to agree that there are some nice 'professional' resources that are now available to hobbyists with the expansion of 3-D printing and virtualization for one-offs and short-run, but for ~$2 an ounce, you can't beat sculpey for a fast and dirty way to mock a case. A friend of mine did a replacement faceplate for his old Nokia and was offered $60 for it. go figure...