I'm very grateful to be in community that supports a laser-equipped Fab Lab. Lately I've been designing and fabricating custom components for my unmanned aircraft, especially components that are easily integrated into existing systems.
Above is a photo of one of my latest creations: a solution that houses a five or six-cell LiPo, an APM 2.5 autopilot with uBlox GPS, and potentially an RC receiver. Other features include vibration dampening via rubber o-rings, and slots to secure the module to the airframe via hook-and-loop straps. The material is 1/8th-inch birch.
Here's a custom acrylic (1/4-inch) mounting solution for the HeliPal Storm Drone quadrotor. Also makes use of 3mm rubber-o rings for vibration dampening. Not sure if it's the ideal material for this kind of structure, however, so I'm anxious to take it out for the first time.
Additional photos and details: http://www.mentalmunition.com/2013/05/you-cant-always-get-the-drone-you-want.html
Comments
Thanks for the tip, Jason. The lab isn't equipped with that material, but from the brief research I did just now on Delrin (aka polyoxymethylene or acetal), that does seem like an attractive option for its strength and durability. Widely available, it seems: http://www.plasticsintl.com/acetal-delrin-sheet.html
If you have access, Delrin is a great material for lasercutting parts for aircraft. It's stiff and really light.