Any good places to get custom headlight covers made?

[Hiryu]

I'm looking to get replacements for my old headlight covers, but I'm not having luck finding places that can do so (anywhere in the world--I'm from the States). I've gotten my old ones scanned and have 3D files that can be used:





The old ones are flexible, but if the new ones are glass, I'm fine with that...I think one of the big issues is that they're curved:




Any suggestions are much appreciated-

Thanks!

[Hiryu]

Thanks for all the info guys-

I was able to search for the specific terms you guys dropped (drape form polycarbonate, Marguard, etc.) and was able to actually find a nearby place that sounds like it should hopefully be able to create a few batches of covers (I've actually driven by it several times without knowing it).

If that doesn't work, then I'll grab the Perspex and warm up the oven.

As far as the covers not looking too bad, that picture was taken earlier in her life (in fact, she happen to win the best in show award right after that was taken). They've aged, gotten a little scuffed, and even cracked since then (ironically, a lot of the wear came from the 3D scanning process that was done in order to get them replaced):



Thanks again

[Hiryu]

The round area with lines was actually carved into the covers...but I'm not worried about reproducing that.

I checked out the local place I found, but they only do large-scale orders (for Boeing, GE, etc.). However, they did point me to a company that does smaller orders, so I'm following up with them next week when they're open.

Otherwise (or maybe even regardless) I might get some Lexan/Marguard sheets and see what I can do myself--It looks like this probably has what I want (though this is not specifically for auto applications, as long as I can cut it and get a slight bend out of it...):
http://www.usplastic.com/catalog/item.aspx?itemid=...

[Hiryu]

The scanning process was either a white/blue light or laser scan, so it shouldn't have required too much contact with the covers. That said, I noticed some strange scarring and even some buildup of material at certain places, so I don't know if they needed to do something to stabilize the covers or even repair them?

[Hiryu]

So far, so good. I talked with the place I was referred to and they say they should be able to make them. I'm still following up on details, but this has been the most promising lead so far...