What about the sub that was made by bonding curved pentagonal sections of
acrylic together? Wouldn't it be more economical to make a few dozen smaller
identical sections that assemble into a sphere or dome? If you mess something
up, you're out one fairly small piece instead of an entire unit.
Also, wouldn't vacuum-forming over a mold be more consistent? A good mold
of fired ceramic or perhaps carbon fiber could be made with the
desired curve and a few small vent holes drilled into it. Set a square of
acrylic into a box, set the mold over the acrylic and seal it to the box. Heat
the acrylic and when everything reaches the desired temp, apply vacuum above the
mold to pull the acrylic to shape.
Then set the curved sheet of acrylic onto a second mold with an
identical curve, but with the sides cut to a pentagonal shape. Cut the
acrylic to match that mold, then anneal it.
Repeat.
What epoxy will bond acrylic together though, and is there a
special bonding method required?