How to cut ABS plastic boxes? Or which plastic to use?

[poorchava]

Holes in ABS can also be stamped/punched and you can make a die yourself (or in other words, it doesn't have to be made out of crazy expensive crystallized unicorn farts like metal punches do)

Back in 1980s I needed to have a hole in a hammond box and that is the method we used.  My partner went to a friend who had a machine shop and he made the punch for us.  I think it only cost $100 or something like that.  He then charged us a buck or so to punch some 1000 boxes as we needed them.  Very clean holes.

On top of that stamping allows for true included corners,  which milling doesn't because of tool radius.

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[george graves]

Bad example. A wood burning stove has to be appropriately sealed and vented to the atmosphere.

I'm sure all wood stoves were "appropriately sealed and vented to the atmosphere" for 100 years.

I'm not sure why you are so fervent on this subject....I'm just amused - but mostly curious. What's up with that? Why do you feel so strongly about it (not that you're right BTW)

[tggzzz]

Bad example. A wood burning stove has to be appropriately sealed and vented to the atmosphere.

I'm sure all wood stoves were "appropriately sealed and vented to the atmosphere" for 100 years.

I'm not sure why you are so fervent on this subject....I'm just amused - but mostly curious. What's up with that? Why do you feel so strongly about it (not that you're right BTW)

I dislike sloppy analogies, especially when mixed with false "information".

I dislike statements that, if followed unthinkingly, can lead to people harming themselves - or worse, innocent bystanders.

For the avoidance of doubt, I don't care what adults knowingly do to themselves, and am not worried about paying my share of their medical bills.

[george graves]

Whatever tickles your pickle dude.

[cncjerry]

I cnc mill ABS and other plastics all the time.  If you are cutting thin material then use a single flute cutter as others have said.  Also, you have to mill a couple to get the speed/finish correct.  There's all kinds of alternatives but if milling works then that would probably be the least expensive for a small run.

[Teledog]

If you, or someone you know is good with 3D CAD (Solidworks, etc.), you might design the enclosure (.stl file) and print them out on a 3D printer?
I've found a lot of custom enclosures that just happen to fit my projects on the Thingiverse website - do a search!
G' Luck!

[poorchava]

That's a bad solution. Even a high end 3d print doesn't come anywhere near injection melding and machining. On top of that 3d printing is expensive as hell for anything more than a one-off.

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[george graves]

That's a bad solution. Even a high end 3d print doesn't come anywhere near injection melding and machining. On top of that 3d printing is expensive as hell for anything more than a one-off.

Sent from my HTC One M8s

No all projects need the smoothness that injection molding provides.  Also, I can 3d print a "hammond" like project box for less then what it would cost to buy. Throw in shipping and the time to wait, and it's a done deal.  Not that I ever do that.  I use my 3d printer more for making jigs and such.  It's really good for stuff like that.