vacuum forming alternatives

Many enthusiasts have explored various materials for vacuum forming. For example, inexpensive plastic items found in households, such as buckets and garbage cans, can be suitable materials. The standard thickness for a forming plastic is approximately 0.080 inches. Is anyone aware of a specific type of plastic that meets this thickness requirement? Additionally, I am curious if anyone has tried using such alternative materials for vacuum forming. If you have any thoughts, experiences, or ideas, please share. Perhaps there are great tutorials on Google that I might have overlooked.

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I have been active on several forums, and as a passionate enthusiast, I find great interest in creating costumes and mannequins for custom home theaters or game rooms. Throughout my exploration, I discovered that a significant technique for crafting impressive costumes involves a method known as vacuum forming. My question is not necessarily about the technique itself but rather about the materials available. While there are several plastics deemed suitable for vacuum forming, many of these alternatives seem beyond my budget, considering my age of 16. Still, the idea of using everyday plastics like those found in inexpensive household items intrigues me. I urge anyone with experience in this domain to share their insights or any helpful resources.

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A question for the silicone mold makers: which method is more effective for removing bubbles from silicone, pressure or vacuum? I have observed several YouTube tutorials and have a basic understanding of the process, and I’m eager to try it out. I own a vacuum pump that achieves 29"Hg and have modified a pressure cooker to accommodate my AC fittings. Thus, I can use it as either a pressure chamber or a vacuum chamber, depending on my preference, with the only limitation being the interior size. With this flexibility, which method should I choose when molding to yield the best results?

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To effectively remove bubbles from the silicone, you should vacuum the bubbles out (often referred to as boiling) before pouring your material carefully to avoid introducing new bubbles. This technique is effective about 99% of the time.

Once the bubbles are addressed, you can choose to mold the part under pressure. If you decide to use pressure molding, you should ideally cast each product under the same pressure to prevent any distortion in the silicone due to atmospheric changes. For those planning to pressure cast resin pieces, the silicone should also cure under pressure. However, if you're only casting regularly, you can let the silicone cure at normal atmospheric pressure. While most casts experience minimal distortion, some cases can exhibit noticeable warping, especially when trapped air remains in softer silicone.

Generally, resin parts are pressure cast to eliminate air. Due to their firmness after curing, air bubbles that expand upon returning to normal atmospheric conditions won’t distort the casting.

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