What do Storm Troopers, and your household vacuum have to do with each other? Storm Trooper costume armor was made (and can be made) using Vacuum Forming.
What is vacuume forming? This…
Vacuum Forming a Cube!
vacuum Forming a dog dish.
Isn’t that the coolest thing you’ve seen all week? But wait! There’s more! Vacuum forming can be done for small things, or HUGE things. Plastic hunting boats are made by vacuum forming a sheet of plastic into the hull. I first saw these about 8 years ago, and at the time, the only DIY one I had seen was large, and would cost $500+ to build. But! My wife and I are going to build a construction toy table (a table for playing with legos / erectors / and k’nex). And, we need some special sized bins, that I’m having a hard time finding for cheap. Then, I remembered vacuum forming, and did a quick search. Low and behold! You can build one for about $20! Using your oven to heat the plastic instead of a special heating element. Yay!!!!
Here’s some more machines for your viewing pleasure.
A professional Vacuum Forming Machine
From all the video’s I’ve watched, and websites I’ve read, people have successfully vacuum formed lots of plastics. My guess is almost any plastic, but the ones I have read about are ABS, PVC, Acrylic, Poly(something or other).
So, here’s a few videos that show some home made vacuum formers. A thorough build is shown in the last video, which is from make magazine video, although I HATE their staples… CHEAP! I prefer this one:
This is my favorite. If they added the window screen like one below, it would be perfect.
Quick Demo
Professional Vacuum Forming with Acrylic
It’s really long, only the first 4 minutes or so are good.
Make Magazine’s Vacuum Former
Tiny Vacuum Former
A Way to get more detail!
By putting a piece of window screen over the pegboard, and turning the vacuum on before you put the plastic down, you get a better forming, with more details.