self made undertail

[GeeP]

To drape form you'll need an accurate model of your intended shape, avoiding curves that require the material to shrink or expand.  For a onesy-twosy you might try building your shape up from quartersawn mahogany dried to 5% MC or below followed by a felt backer.  Use solid wood, the glues in plywood won't stand up to the oven temperature.

You might also try making the form from a high Tg polyester tooling resin and chopped strand mat.  Cover this with felt.

Temperature-wise you'll need in the range of 375 degrees F.  More if you're drape forming, less if you use a vacuum bag.  The temperature is too low if it won't drape to your shape in several hours (or your shape is too complex).  The temperature is too high if the felt leaves an impression in the plastic.

Search the web on "drape forming", "vacuum forming", and thermoforming polycarbonate, you'll find plenty of information.

Little tip:  The best way to finish polycarb and leave a smooth edge is to use a carbide beading router bit.    

[badguy]

Holy crap GeeP, you know everything!  You're my hero

[Alphamazing]

To drape form you'll need an accurate model of your intended shape, avoiding curves that require the material to shrink or expand.  For a onesy-twosy you might try building your shape up from quartersawn mahogany dried to 5% MC or below followed by a felt backer.  Use solid wood, the glues in plywood won't stand up to the oven temperature.

You might also try making the form from a high Tg polyester tooling resin and chopped strand mat.  Cover this with felt.

Temperature-wise you'll need in the range of 375 degrees F.  More if you're drape forming, less if you use a vacuum bag.  The temperature is too low if it won't drape to your shape in several hours (or your shape is too complex).  The temperature is too high if the felt leaves an impression in the plastic.

Search the web on "drape forming", "vacuum forming", and thermoforming polycarbonate, you'll find plenty of information.

Little tip:  The best way to finish polycarb and leave a smooth edge is to use a carbide beading router bit.    

I love you.