I have this idea to take a 1/4" or 1/8": 4 X 8 or 4 X 4 sheet of something light weight but ridgid(MDF, hardboard, styrene, foam, suggestions) and cutting it in to an amorphous / free form shape. Possibly I’ll cut two sheets the same size and shape. But it would need to be cutable with a skill saw, table saw, sawzall or multi tool and paintable. Then I want to cut a strip of undetermined width to attach to the perimeter to make a box. I’m going to mount the box flush to the ceiling. I have a bunch of white micro LEDs, an Arduino and battery that I was going to use for another project that failed. I want to drill tiny holes in the bottom of the box and insert the LEDs. I’ll hide the battery, wires and Arduino inside the box. I do have a device to change the battery voltage down to what the input on the Arduino can handle so maybe I ditch the battery for a 110 wall plug.
I’m looking for suggestions on stiffening the whole structure to keep the large flat sides flat. Or a skin material that can stay rigid without the need for a skeleton. I had thought about making a thin lightweight skeleton out of something and then attaching the skin to that. Possibly making the skeleton out of extruded aluminum L or square tubing. Or thin steel (possibly too heavy). I’ve never welded before and don’t have a welder so it might have to be rivets if I do metal. I could cut thin strips of the skin material or acrylic and glue it edge on as ribbing. Any and all suggestion are welcome and thank you very much ahead of time