Chris-
We fabricated our entire electronics enclosure in 1/8" lexan
. The holes are made with a variety of tools, small 1/2" holes are made with a step drill, the larger holes are made with hole saws, and other cutouts with a fine blade in a jigsaw
. The structural tabs are made with a pair of 3" duckbill vise grips and a heat gun
. As for radius, we didn't really measure it, we just allowed an extra 1/8" of material when bending the tabs. The whole deal is pop riveted together to make it robust and keep it lightweight.
Good Luck to you and your team!
Dana