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3DPrinting
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I got the general idea from the iPod Mini
Its basically a metal flatish sort of cylinder with a central chassis that slides in and out. I've used this technique a lot for printed enclosures because it feels pretty strong to me, and usually pretty easy to print, even with overhangs, since its such a regular shape. You also dont have to worry about applying components to the inside face of the case, since the whole things just slides in.