I reviewed the Plastruct offerings last night.
(1.) You can get the pieces in double sizes, twice the length, might be helpful.
(2.) Some of the square/rectangular pieces may work in the open spaces.
(3.) I was seeing three different types of plastic tube, Butyrate, ABS, and Styrene. You may want to ask Plastruct which of the three is best for this application.
(4.) I've bent a lot of Sch 40 PVC electric conduit, with a hot box heater. This bender, about 6 ft long, has a larger electric heating element and is designed to allow rotation of the conduit for even heating. There is a conduit plug set, as has been mention, to close both end of the pipe. This maintains round and allows for tight bends. Gloves and protective clothing are required, the stuff gets very hot. Soft plastic conduit out of the heater is like spaghetti. Cooling changes dimension, and shape, which is taken into consideration. There can be considerable waste, depending on application.
(5.) Quick bend of Sch 40 PVC conduit 3/4" and may be 1" can be done with a small propane torch, but usually also is accompanied by burn marks on the conduit. Hand held, hair dryer type, heaters can also be used, again caution about burn marks on the plastic. Keep in mind that the material and thickness is way different from what I have experience, commercial PVC conduit application.