Lexan cuts easily with a router. I could do it, but a router would probably cost the same as shipping

How big is it and can you put up a pic of it?

For this you could draw it up in CAD and find your nearest CO2 laser. They can cut it out for you very precise! I do it here at my work all the time. It could even be made from other material if you want.

That's what I was thinking. Just needed to know if it would fit in my router.

We can laser PETG or acrylic. Send me a pm if you haven't figured something else out

Acrylic can get VERY brittle when heated. In my experience, I don't laser cut acrylic for anything I want to last. I once cut out a nice template only to come in the next day and it was shattered into about a million pieces

We laser cut acrylic daily.... And actually to form acrylic we heat it...

Can Lexan be placed in a kitchen overn (low temp, maybe 250 f) to mold it? Thinking about trying it but only have one piece to try and make a plastic part from. That stuff (Lexan) is not very cheap I thought about a heat gun I have in the garage but then realized that s pretty hot (more than a hair dryer) and I would prob. screw up without substantial practice time on that material. I do not have the coins to practice on Lexan

Thoughts?

Really? Polycarbonate? My CO2 laser would turn it into a black charred mess. I think you're probably cutting Acrylic or PETG or using a fiber or Yag laser

You can do it. I have faith in you.