I think another point I hadn't included was the flexibility I had with prototyping different boxes. The hardware was changing all the time, and being able to just 3d print another revision was very convenient.

If I did something like that with styrofoam, it probably would have gotten pretty expensive. The precision you get from printing was also a plus, as there needed to be slots for cameras, antennas, and circuit board mounting holes.

Seems like the simple solution is a Styrofoam sheet, a $10 hot knife and some glue solves the customization problem almost trivially.

In my intro Industrial Design class long ago we fashioned styrofoam and many other kinds of foam into every shape imaginable with a hot wire, some utility knives, and contact adhesive. A wood rasp worked well for organic and rounded forms (wear a mask), though that’s probably not needed in this application.