On Mon, Dec 6, 2021 at 9:42 AM David Bridgham via cctalk <cctalk at classiccmp.org> wrote: Cool. Yes. I'd rather not demolish my only indicator panel. I was planning on demolishing a blank (I have a few short blanks, but most people do not) I have a small 40W laser etcher that I essentially haven't used since I have had access to large-format 80-120W laser cutters. As for tools, I can rent a 4'x8' Shopbot router at our local Makerspace that can turn out the light blocking bar or, from your file, the frame. We also have a local company (IC3D) that makes cubic-meter 3D Printers and makes their own filament from pellets, keeping costs down. The founders are friends of mine and I've helped repair sensors on their manufacturing line. If I had an STL, I could get a bid on what it would take to 3D print one. It wouldn't be as smooth as a machined PVC foam milled one, but it would be strong. With a little post processing, a 3D Printed frame may give an adequate look. Just a possibility. I haven't worked with PVC foam much but I understand the principle. That sounds like a power problem. Normally, Delrin lasers quite nicely, at least at 80W. Thick stuff is hard in any printer because of lenses, beam diffusion, etc. We sometimes have problems with 1/2" material of any kind in ours. I've done some stuff in 2 passes, one high, one low (refocusing/repositioning Z axis between job runs). We also have multiple lenses for different focal points. One is only good for etching/surface work, and one is good for cutting 3/8" and thicker materials. We usually use the middle one since 99% of what goes into our laser is 3-6mm stock. I could take a look at it, I have some background in making Qbus and Unibus interfaces, but how useful I'd be depends on what kind of feedback you are looking for. I did notice that. I have no idea what to recommend. AFAIK, DEC just used an acrylic with a specific surface texture. The only stuff I can get is like what you have - smooth as window glass. Cheers, -ethan