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Beyond Design

Project by

Beyond Design
Chicago, Illinois

General Information

A simple case designed to utilize the flexible properties of polypropylene. The Design itself is very simple, with plenty of room for engraving and customization.

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Material Description Price
Black HDPE Sheet

Black HDPE Sheet

Thickness: 1/2 in, Dimensions: 8 in × 12 in, Type: Single color, Color: Black

$7.49

Polypropylene Sheet

Polypropylene Sheet

Dimensions: 12 in × 12 in, Thickness: 1/4 in

$5.99

$13.48
from Inventables

1

Mill Polypropylene sheet

Use a 1/16" endmill to mill the channels for folding as well as the overall profile. Polypropylene is the ideal material as it will bend without cracking or breaking.

Use this EASEL link

2

Mill End Caps

Use a 1/8" endmill to cut your cap pieces. I used 1/2" red HDPE for its bright color and durability, but this could be any material that is tough enough to hold the polypropylene in shape. Choose whatever color/material you like best.

Use this EASEL link

3

Assembly

Start the folds in the polypropylene by hand. If the material is too stiff you can use clamps to squeeze and hold it in shape while you put on the endcaps. Remove the clamps and the material will expand to hold the endcaps securely on. No glue is needed, although you can certainly add some for an even more secure fit.