A thermally and structurally optimized disaster resistant housing for a vertically stacked array of computer digital data storage devices such as hard drives is provided. An external, fire resistant housing has an internally mounted water resistant enclosure for the array. The water resistant enclosure includes a plurality of much thicker plates than known which significantly increase dissipation of heat and simultaneously greater increase the crush and impact load resistance of the device. An automatic method is also provided for producing complex molded gypsum or cement components.