Is there any way you can dope polystyrene or similar material with something to make it hard and strong?
I am thinking you could cut a reprap frame on one of those and then paint it or dip it in something to make it hard and rigid. Perhaps a more open structure foam (Like Oasis floral foam) would be more suitable as this would take a strengthening resin more easily.
This would make mass production very cheap as you could make several similar parts at once.
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