In SX Microcontrollers, SX/B Compiler and SX-Key Tool, George Herzog wrote:

Vacumn forming is really easy.  I remember several old articles [1960s] that demonstrated do it with a shop vacum and heat lamps.  The modle was set up on a platform made of masonite [the kind that is pre-drilled to hold tools].  Apparently, the plastic sags mostly and the negative pressure to add detail doesn't have to be very high.

This is ideal for low production runs.

Most of the injection mold plastics require hugh quatities [10,000 units] before a real savings is reached.  You have a lot of design cost, mold construction, test runs, and so forth.

What you see in the XBox is likely a color change of the original product using the stock mold.  It seems that in Asia, when the manufacturer orders 10,000 units, someone runs off a few 100 odd ball colors to make money on the side.  They go out the backdoor of the OEM supplier.

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