Using pre-painted sheetmetal might be easier-cut, bend, drill, etc.
Lexanš is an excellent transparent polycarbonate plastic sheet
available from thin (<1/32") to thick (>1/2"). It can also be formed
cold like metal. It can also be heated in a common oven or with hot
plates, infrared lamps, etc. to where it is like soft toffee. Then it
can be formed into complex shapes by forming around a form or mold,
and it can also be vacuumed into a mold cavity.
Hope this helps,
Winston
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