Wrapping my mind around what a GlowForge generated case for a GlowForge would look like:
you obviously have to use 1/4" material. And while I would love to think up a viable solution for the non-pro Forge owners… I am not going to try that right off.
So, you have 20" width to work with, and 1/4" depth. With the 20" width you cannot make a single layer case, which is fine since 1/4" material ought not to be sufficient anyway.
from Shipping and customs:
So we would be looking at something like 46"x29"x28" and 110 lbs.
Along every side of the case, you will have a seam to deal with. Obviously this seam will run in the 49" direction since otherwise you need 3 pieces to run perpendicular to that direction. Though having your two layers not sharing an axis will be a wise move if you build this case with wood that has a grain.
Okay, so you cut two slats per side, one at 20" full width, and the other at the remainder (8" or 9"). You do two such layers per container side, placing the 20" portion on opposite ends per layer so that the seams are not aligned.
Leave holes in the panels that you can stick stock material through, then twist key-style to lock them together (Like the last item on this list, the double lapped slotting joint with key). Or if you used acrylic, use acetone in the space between layers to chemically bond into a 1/2" layer.
You will want padding, especially since those key-hole penetrations will be sticking out and pointed at your Forge. Egg Carton foam (the stuff with pointy bits on one side) would be decent here. But as others have stated… not JUST that.
I could see doing a doubled case. The weight will increase, and the awkwardness to carry. But at 110 lbs and 46" x 29" already, I don’t picture people lugging this around briefcase style anyway. A carrying cart (or built in coasters) is reasonable.
So… let us add an inch in each dimension for packing material inside the inner layer, then add 1/2" for that inner layer, and then another inch of packing material and finally an outer case.
Now we are making two double layer cases:
50"x30"x30" (Yes, 29" it should be, but I prefer a nice square, and extra padding on the bottom makes a ton of sense, doesn’t it?)
and another around that at
52"x32"x32" (yeah, I said 1" of packing material and 1/2" for the inside case, but I don’t want to plan with 1/2" measures because decimals and fractions are messy – EDIT ON RE-READING… of course you have to add 1" since there are two sides at 1/2" each. So I wasn’t adding arbitrarily, I just had no idea that my subconscious mind thinks the rest of me is an idiot. This also means only 1/2" of padding along each side between cases.)
Overall, fairly reasonably achieved. You can even pre-cut the holes for where you would attach the casters (whatever the right name is for wheels on a cart. And since I can never remember if the front or the back should be the side with the swivel joint, make all four have it). You could even add an extra panel on one end to affix a handle for pulling it behind you.