This is the documentation of the process for my 2nd prototype testing with another method.
This is with the considerations of the design refinements made after the initial test model.
Honestly, this is a much more complex method. The overall outlook of the prototype may seem clean and simple but the internal parts and the fixing technique is not as friendly as the initial method. The double flaps on the top and bottom are hard to control. When slotting in the bottom parts the top seems to be flapping around and hard to hold them together. Other issues includes the contouring of the sides which do not gel or gives a consistent flow.
Above that, this structure seems to be a little bit stronger as it has double layer outer shelling surface and more interior support.
A solution for a newer method is still underway.