Messing around with 3D printing
I've been playing around with FreeCAD, mainly showing off on the AtariAge forums, but I also decided to try modeling a ThunderCat part. This is my first attempt, the blank panel where the antenna or T/C switches go.
I sent it out to Shapeways to see how well it fits. Once I refine the model, I plan to model all three variants, plus probably one with an extra-wide cutout.
I've tried to make a few design improvements along the way. The screw holes are reduced from 5mm to 4.5mm, and the plastic at the holes is 4mm thick. I've also rounded the insides of the shafts so the flat portion smoothly transitions to the sides. Hopefully these will result in much stronger screw-on points.
When I get the model from Shapeways I'll post pics. I chose the cheapest materal, "white, strong and flexible". I have other things in that material: it appears to be very strong, and it's slightly rougher than the stock plastic (nothing that light sanding wouldn't fix). It wasn't cheap ($75!) but the cost is based purely on volume so the blank version would be the most expensive.