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Vacuum Former

Using a toaster oven to accurately form plastic

A simple box was constructed. The internals were all sealed with caulking to maintain an airtight seal.

 

The top of the box consists of a metal grating, this is where the air will be "pulled" through, to form the plastic.

A tool was designed in Fusion 360. This is the form that the plastic will take shape around. 

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thie piece was machined out of a block of Delrin

The form tool is placed on top of the grating. 

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The plastic, which is heated in the toaster oven will be placed over top of this. 

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A shopvac will be used to pull a "vacuum" and suck the plastic into place

Here is the PETG plastic being heated in the toasted oven.

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The key is to only let the plastic sag about 50mm before removing it. 

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Too much sag, and the plastic will get creased during the form, too little sag and the plastic won't get fully formed

Success, A good form!

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