What's a good cost effective way to make a large plastic body/case?
I plan on making around 50 of these for an initial run. Cost is a factor to prove that a profit could be made while not outsourcing the work involved. My goal is to keep this cost below $30 each part, but could go as high as $50.
The body will need to be hollow, and has initial dimensions of 18"x12"x8". It does not need to be one piece, several pieces that can be assembled is actually ideal.
Here are a few options that I have looked at as well as my concerns...
-Injection molding- I worry about the setup costs for equipment let alone the space needed.
-Resin casting - I worry about it being too brittle and effectively making workable molds for assembleable parts.
-Resin coated foam - I worry about the look of quality as well as the cost of foam.
-Vacuum forming - My main concern is the cost of sheet material.
I'd appreciate any input, whether it is to add more ideas or to address concerns that I have.