I redesigned my sample prints to be both skinnier and taller, I think that more closely resembles the real thing. I then made them with a 1.6mm, 2.4mm, 4mm and 8mm thick outer wall, and 2-3 0.4mm walls when printing. The first two effectively have solid walls when printing with either 2 or 3 walls (that is getting confusing to say!). The other two have some percentage of infill between the walls.One of my questions is how much plastic is needed to make a solid outer wall. Ideally we use the bare minimum that gets the job done, it makes printing faster and reduces the cost. Anyway the first two samples while stiff can still be flexed with moderate pressure while the 8mm sample is rock solid. The 4 and 8 mm prints also block significantly more light than the thinner samples. I am curious to see how much paint will improve that. I still need to finish printing out the full samples and stick them outside to see how well they stay cool.