I think there's demand in the DIY audio crowd for some nice 6" port flares. The Aeroport PNR is too difficult to obtain, and from what I've read has a few drawbacks making it more difficult to work with than it could be. First and foremost, finding the right kind of PVC to mate to the flares is difficult. Even if you DO find the right type of PVC and the flares fit onto it, I believe you have to sand the inside of the tube down so that the seam where the flare and tube meet is flush. Yuck. Also, there is no "mounting flange" on the Aeroports like there is on the familiar 4" precision ports. The mounting flange gives you a huge amount of flexibility and makes installation easier and more secure. I've been toying with the idea of modeling my own, better design for a 6" flared port. One that fits the most commonly available type of 6" ID PVC pipe, has a nice mounting flange, is thick and strong, etc. The idea would be to use rapid-prototyping technology to build the actual flares. I have no desire to invest in injection molding or get into the business of selling flared ports. My first question for you folks with RP knowledge: is this possible? For example, would a 1/4-inch thick LOM prototype be strong enough to hold the weight of the PVC pipe? Would humidity make it expand or contract? Would the surface be smooth enough, or could it be made smooth enough by sanding/painting? Next question: Would it be cost-effective ($60 or less for a pair of flares) to bring these things into reality? What I'd like to do is produce a sliced CAD file, put it on my website for DIY subwoofer hobbyists to download, use, modify for their purposes, etc. Free of charge, of course. I'd also like to find a hobbyist-friendly RP service bureau that can produce them relatively inexpensively for us DIY folks. What do you think? Is this a pipe dream (pun intended)?