Or another example, how do you cut the rectangles for the USB ports in this picture:
Ive read a few threads about cutting in plastic and its always blah blah about drilling and using a jigsaw.
I want to put a set of buttons beside my screen sort of like this:
I want the buttons to be lit with LEDs so I think these would work best:
Except, how do I cut those small little rectangle openings into my bezel (the picture is someone else's bezel with a screen in it):
Better yet, use a laser cutter. Most people that have them wont mind doing it. Some will make you pay a few bucks, but it is exact and fast. And it is a laser so the overall cool/geek factor goes sky-high.
On a side note, where did you source those button thingamagiggs that go over the pushbutton knob?
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If you don't have that access, some very careful -- very, very careful -- cutting with a simple X-Acto knife and a steel straightedge can get you there. If you have a template, it's easier, but you really can cut straight lines in plastic. Cut a fine, shallow line to mark the shape, and then deepen the cuts slowly and gently.
This is slow, precise work, and it takes attention to detail. Practice on scrap, and then go for it. The keys are to go slowly, keep all your cuts gentle, and use good, sharp blades. Cut less than you want each stroke. You can do it.
If just enough is really good, then too much ought to be perfect.
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Guess I just have to buy really, really small files or find a local laser cutter.
CNC mill...I've had intricate acrylic machined perfectly for my needs. Not the cheapest solution, but you draft it up in CAD and you get exactly what you asked for.
how bout a dremel tool?