Tell us about yourself!
You dont need that fancy stuff. But investing in a drill would be a good buy lol. Harbour freight has cheap tools like the rotory tool would work really well for you and its only about 15 bucks us. Keep me posted on your next build you have the mind of a inventor.
Actually use 1x4s its roughly the same thickness as the foam but stronger and you can stain it and clear coat it and even assemble it with hot glue. Costs maybe 3 bucks.
Hey man not trying to sound mean but its a killer project idea however use all wood instead. Looks sloppy as is but with wood would be pretty good. Your smart with the electronics i know you can build a box for that thing. Good job overall.
Really in my opinion as long as your not breathing in styrene or #7 plastic fumes or pet you should be fine without a resperator and stuff. As far as 3d printing goes they could use anything. But generally speaking id imagjne they would use either low density polythelene or medium density or maybe even poly proplylene. Just based on there low melting points that is. One way to tell what you have is this. If it smells sweet when you burn it its poly propylene (pp) if its kinda a waxy harsh smell its a poly ethelene. Hdpe, ldpe, mdpe. Anything else kinda stray from in my opinion.
Also there is a general match ro most plastics. On cars its normally ABS which sucks use a hdpe filler. For most everything else use #2 or #5 and you should be good to go
Zip ties are actually a bad choice for filler for 2 reasons the first is the plastic is actually a styrene polymer and is very toxic to us. And 2 when burning or melting it will boil or bubble it would be better to use a milk jug or hdpe. I was a supervisor for a plastic company for 2 years.