OK,
The best thing about plastic is that it's cheap!
It's when U produce specialised, small quantity components it becomes more expensive.
Your in the US I take it!
If your a "small timer" then Injection moulding would be out of the question, however with a bit of advice from a University or academic establishment
(UK example -
http://www.brad.ac.uk/acad/irc/) coupled with your fantastic CNC skills, well the sky's the limit.
I'mmm sure there is a US equiv that could give non-biased advice on this subject, indeed it would be a fantastic project for a student of material science etc.
This is a very expensive approach to tool up and test however
So I would advise U go down this route
Try a plastics forum for contacts, and impartial advice.
e.g.
http://www.plastics.com/pforums.php see what other peeps have to say.
Right what would I do in your position - for a more "suitable" alternative (in sheet form) the trick is to get the right polymer AND the right grade........this is where the likes of GE plastics come in.
Hav a go at this and see what pops out
http://www.gestructuredproducts.com/...x.jsp?FormID=1
Lexan looks promising
If you contact them* for advice they will point ya in the right direction, in fact you should be able to get a free sample!
Did ya know KEVLAR(R) was developed for space!
Bullet proof "glass"? LEXGUARD(R)
*Polymer manufacturers NOT warehouses, DIY stores etc....
Mat
