Progress is slow on the pibow multi layer raspberry pi box.
Feel like I’ve managed to trash at least as many attempts as I’ve had successful. It’s been a slightly frustrating day.
The results are looking pretty rough at the moment, planning to sand the exterior smooth one all layers are complete.
On the bright side I’m getting some fairly consistent cuts. But the hdpe flexes a little once most of the shape is cut out. And I had a few failures with the shape coming loose too soon.
Next time you will know to add tabs to your gcode files. 
When I say tabs, I mean you will cut the majority of the outline of your part leaving short sections that you don’t cut until you have completed the outline. I am pretty sure PyCAM has the tab feature available.
@Kyle_Kerr I had tabs, but apparently not large enough or frequent enough…
@Daniel_Would
You might want to try getting some Micarta to work with. Phenolic resin sheet is very stable material. There are even some tutorials on the net about making your own homemade stuff. From what I’ve seen the homemade stuff doesn’t look too bad. Although usually people try to make theirs wavy on purpose for grain. It is hot with the knife making crowd at the moment for handle material. I have a supply my grandfather got off an old machinist’s wife who’s husband had died. But I keep my eyes open for when I run out. Micarta isn’t the cheapest stuff in the Universe unfortunately. I guess it isn’t too bad just buying it for what it is either though.
There are merchants on Amazon.
I knew a guy who did work for another guy who made the resin for Colt pistol handles I think it was. So he ended up with a sheet of that. That stuff was wild! Apparently the mechanism he used to put the swirl patterns into the material was proprietary. You could have hung that sheet on the wall as modern art. But I don’t think that stuff is generally available to purchase. If it was you’d probably have to be sitting down when the price was quoted. Because I think the guy charged fine art prices for it too.
