Step 4: cut your material

For a thicker piece, I used a combination of a hacksaw (with my piece clamped) and a heavy-duty snips. For the thinner piece, a razorblade worked well.

Cut out the box shape from your material. 
Sand or file the edges.
For something that was a unique shape or function this technique would be OK. But, unless you have access to a very expensive machine and free materials, it would be cheaper, easier, and more professional looking to buy off-the-shelf from any number of electronics enclosure manufacturers. <br> <br>Just my take in DIY stuff. <br> <br>Ken
I prefer to root around in my junk box(es) and find an enclosure that works. Maybe one that has the power supply or connectors I need, or just looks cool.
Cool instructable, one thing I thought I would add is if you slope your mold with a minimum 3% grade, you wont get as much webbing on the sides of your form &amp; it will be easier to take out the mold. Also, polystyrene is one of the easier plastics to thermoform but if your project is outside it will not hold up to UV light for too long.
I love it! great job! :0

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