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The title pretty much sums it up.

Do you make you own screen? If so what thickness lexan do you use? What do you cut it with? What tips can you gine that make it easier?
Polycarbonate has to be hot formed, and I've never seen it done without a mold.

General rule with composites (including plastics) if you can buy it pre-made ... Do so! It'll cheaper, better, and faster than you can do it. Unless you happen to live in a composite fab shop
 
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