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I'd like to mock up a quick prototype of a chassis assembly for a type of cart, which, in production, would be composed of CNC bent aluminum extrusions (hollow, approximately 5/8" circular profile), and connected using plastic joints. I'm wondering if anyone could recommend methods for prototyping the tubular components.

I'm considering using PVC, but I would like to use something I could bend and shape angles into relatively easily.

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  • $\begingroup$ use metal conduit. $\endgroup$ – DLS3141 Aug 22 '16 at 11:00
  • $\begingroup$ If weight isn't critical in the prototype, copper pipe and common plumbing tools (pipe cutter, bender, unions, tees, solder) would be one option $\endgroup$ – user_1818839 Aug 22 '16 at 14:15
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EDIT - I've solved this issue after a bit of searching for similar application requirements, so I'll post my solution:

Applying a bit of heat using a heat gun to sand-filled PVC pipe allowed me to slowly bend the pipe into my desired shape. The sand prevents the PVC from collapsing inward as it is bent.

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  • $\begingroup$ This should be a comment, it's not an answer $\endgroup$ – DLS3141 Aug 22 '16 at 18:28

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