Hi guys,
When you have air with moisture in it, the moisture will condense into liquid water (fog on your lens) when the temp reaches the DEWPOINT.
If you have warm humid air in your housing because you opened it on a tropical island, than that moisture will condense when the setup gets put in colder water - if say the dewpoint for that moist air is 78f
So closing your housing in a cool DRY environment is the best thing you can do - so airconditioning is a GOOD place to open and close it. If there's no moisture trapped in the camera and housing then there can't be any condensation.
Now on to the other topic - Al vs Acrylic/Polycarbonate. The Al is a much better heat transmitter than acrylic/polycarbonate. That means it cools off fast, so water if present will condense on the inside of the aluminum, as opposed to the inside of the port glass. That's a good thing.
With acrylic, the problem arises when you use an acrylic or polycarb. housing with a glass port. The glass cools fastest and this is where all the water condenses...:-( This is not a problem with Ikelite housings because they don't use glass ports, but it is a problem w/ the small consumer camera housings.
Cheers
James