When I worked at McFarlane Toys we used 3D prints for some of the toy master patterns. I saw this image on the web a few years ago and used it for a personal project. I am learning more on SolidWorks so I drew up a file. I did some changes and came up with this. Partially hollow for electronics. I prepped the parts by giving it about 3 coats of primer paint to smooth it out more. I made an RTV silicone mold as we did when I worked at the toy company and then cast resin parts as shown here.
Here it is after all resin parts are cleaned, painted and assembled. The two square buttons in this picture were laser cut in plex out of a different shop.
Cool end product! What Shapeways material did you use for these parts? We all the parts printed together or did you have separate files? Thanks.
I used the "black strong and flexible" and "alumide". I sent as separate files. Easier to keep track of.