• I plan to glue the watch together with either low melt hot glue or B-7010 double sided tape to be able to take it apart relatively easily. The surface roughness might play to my advantage there.
    PCBWay will do aluminium and stainless SLM for about 3 times the price. Even titanium for a bit over 100$. JLC3DP has nylon SLS options for even less money than metal SLM so that would solve the faraday cage problems. I'm currently hoping to just connect the whole case as aerial and maybe it works well enough to be usable. Probably not because the whole tuning will be completely out of whack, but we will see.
    I will take some measurements and compare with the CAD file to post here when the thing arrives. There are some videos [*1] where the tolerances seem to be pretty nice. Better than 0.3mm at least.
    If I loose GPS anyway because of the metal case, could I just remove the "antenna block" for more space inside the case or a slightly smaller case design? Or is it needed for other stuff as well? The barometer hole is on the same side in the original case.

    @Ivor: My mill is a set of old stuff I bought used for relatively cheap, Proxxon KT150 and BFB2000 (filled the pipe in the back with concrete) as the base and a Kress 1050 milling motor. It just about does aluminium well enough but it takes a lot of time doing this manually and it is very easy to make mistakes. If I had known how cheap 3D printing services had become I probably never would have tried to mill the case myself.

    *1:
    https://youtu.be/mrp28hZ_Qu0?si=7nVoD4aG9clbomw2&t=335

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