To be honest, I'm still not entirely sure how the shell was designed and made. That's the magic of teamwork, sometimes someone else does the thing! All I know is that I exported a 3D model of the populated board from KiCad and handed it off to the mechanical teammate. From there we printed a series of tests to make sure the fit was good.

Once the mechanicals were good the project was shipped to an artist on the team who added exquisite spaceship detailing. There was a bit of back-and-forth to make sure it was manufacturable with injection moulding, and then it was off to the manufacturer, Protolabs. We had them made in two colors and both came back amazing!