PS2 Designing PS2 replacement housing

[Masumi Arakawa]

Forgive me if this isn't the right place for this.

I have a few PS2 slims that could use a new housing/shell however the only option is either buying a used one from a broken console on eBay or buying a cheap knockoff from AliExpress.

I used to see plenty of ghost cases a decade ago however those are pretty rare now too.

I was wondering if it would be possible to design our own case and have it either be molded or 3D printed.

To be honest, I have no idea how to go about designing this and I know even less about 3D printing.

Would 3D printing even be worth it or would it design an inferior quality case?

Would this be an expensive endeavor?
You guys seem pretty knowledgeable from the threads I've read.

I've thought about this for a while so any input would be appreciated!

 

[DarkMario]

3D printing COULD work, but it would be a pain with all the standoffs, getting a good surface finish, areas with overhangs like the disc drive slot on plate would need supports, etc.

Injection moulding is VERY expensive to get setup and companies don't usually entertain orders under a few thousand it's not worth their time to do.

Those reasons above are probably why you are stuck with used cases or inferior parts from alixexpress who are probably using old worn moulds that were never perfect to begin with. Getting injection moulded parts perfect is a bit of an art as you need to consider the plastic shrinking as it cools, etc to ensure you get a perfect part.