How Do I Make a Case?

The Box Method

This is what most of us on the board end up doing. You simply find a box of an ideal size and shape, and cut holes for the screen, buttons, and ports. You can also use another case, like a modem case or a Sega Nomad case.

Plastic Molding

Molding your own custom plastic case is a great idea, but it takes a great deal of time and patience.

Vacuum-Forming

Vacuum-forming, also known as vacuum-molding, is a practical method if you plan mass-producing cases. They look pretty too!

Here are two more table links found by ···Agent EQzE···:
A smaller, tabletop vacuum forming table, without the heater.
An interesting vacuum forming table which flips the plastic over, with one side being the heater and the other side being the vacuum.

The Frankenstein Technique

This has been pioneered by handhelddc in his portable N64. Instead of using a new case to house all of the parts in a portable, he fused all of the original packaging together. Though the results are not excactly aerodynamic, it works.

Applying Logos and Text

Posted by dragonhead

i know a cheap way to do that too.
just cut out a stencil of what you want it to say with an x-acto knife and spraypaint over the stencil.

Posted by NiN^_^NiN

Use tattoo paper ;) you can buy tattoo paper for a inkjet printer and print on it :)

There are 2 kinds 1 is to rub onto the case other is like a sheet of stickytape but it has the image on the tape :)

Engraving

Posted by SpongeBuell

This case was a basswood box, found at Michael's crafts for about 8 bucks. The dimensions are: 4.63x6.12x2". I was able to put the design on with a laser thing they have at school (it's good to know your former graphic arts teacher) It's off center only because the software is kinda confusing. I am planning on adding everything else pretty soon. For the controller I will cut off part of a broken NES controller and wiring that to the board.