There really are laser services closer than India (absolutely no offence, MOZ), but so far very, very few (none) seem willing to laser things for people. I've got a stale IC for an aluminum ergodox case because the local company isn't getting back with me, and the other one doesn't seem to want to talk to me either, although that guy said they don't have a laser they have to farm it out. Maybe the busy manager is the one I want to keep pestering.
Anyway, I sent the litster files to pololu for a quote, and using 1/16th-inch clear acrylic, it would be $80 -- can't remember if that's shipped or not. I assume the .dxf provided by MOZ (8 layers, if I'm reading it right) would be at least as bad. I've talked to someone here on the forum who says it can be done much cheaper and he can do it ... then he went silent; presumably real work caught up with him.
Sheesh. That's a lot of complaining I just typed out. What I came to this thread to say, was MOZ has, as he points out, written up a nice casefile, and someone else converted it to both .DXF and .PNG which more laser shops seem to say they want, then the .dwg MOZ works with.
But it's a file, and you can't wrap a PCB in a file without a laser and some plastic -- that's a thing of which there's an uncomfortable dearth around here.
So, MOZ -- how thick are the layers supposed to be? And, let's say for the sake of argument, I sent the file off (to a responsive company, or paid the money to BigBlueSaw (who wouldn't take your file as it exists right now but that's another problem)) and said "eight layers, each sixteen gauge stainless steel" (that's around 1.5mm AFAICT) ... any reason your case wouldn't work with a phantom in that form? Or will it short something out, do you suppose ?