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Hi Derek. I'm no expert either, but I'd like to echo what Jim said. Jim has
a beautiful dome made by Greg and it's as big as you can get from flat sheet.
Pouring ( casting ) is an expensive process, and often results in an imperfect
piece. It's very difficult to get a casting with no bubbles. With flat sheets as
a start, you get a very stable piece of plastic, and no chance of bubbles. These
sheets are made 48 inch by 96 inch and the process of making flat sheets is well
developed and almost fool proof. It's a mass production process and as such,
They've got the bugs worked out. If you hire some one, even a reliable company
like the one you mentioned, to make a one-off casting, not only is it going to
be very expensive, but it may contain hidden flaws. If you have lots of money,
and lots of time, maybe it's worth it. The flat piece method is fast and
reliable, and less than half the cost you mentioned. Frank
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