Look up how PVC house window frames are made. They use extrusions, cut the 
corners at 45 degrees then melt them together.
Here's a video on a portable corner welding machine. 

      From: John Kasunich <jmkasun...@fastmail.fm>
 To: emc-users@lists.sourceforge.net 
 Sent: Saturday, October 15, 2016 7:33 PM
 Subject: Re: [Emc-users] Wat OT: Question about injection molding of PVC
Injection pressure will be trying to force the two sides of your mold apart.
That's why injection molds are made of tool steel, and injection machines have 
VERY sturdy construction to hold the mold closed.  I saw a machine that might 
be big enough to make your parts - the mold closing cylinder was about 2 feet 
(0.6m) in diameter, and the four steel tie-rods that held the machine together 
against the clamp force were about 100mm diameter.

Could you make it out of four strips with some kind of joining at the corners?

John Kasunich

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