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!