Laser Cut Low Outgassing Plastic Cutout For Satellite
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colinwarn commented
Find a low outgassing material that can be preferable cutout by a laser cutter. If you can't, no worries we'll just CNC mill it.
CubeSat Design Specification, Page 8, 3.1.8.1 and 3.1.8.2 have the "low outgassing" definitions:
https://www.cubesat.org/resources
You'll find this link helpful for looking up materials:
https://outgassing.nasa.gov/
Cutout should be 0.5mm thick. It need to takeup the full red area as seen in this picture. Holes slightly larger than the ones within it's box must be cut so that the components can continue to stick through:
gregstolte commented
Material is Lexan polycarbonate sheet