Bending plastic is fun and exciting...ok, the amount of enjoyment may vary from person to person...but you get the idea.
All you need is plastic and a heat bender. Luckily, i have access to a heat bender at TechShop in San Jose, CA.
As a note, you should always do a test to make sure that your plastic can be heated and formed. Some plastics like poly carbonate with show black specs when heated, and these will not go away. In addition, I do not recommend heat bending material more than 3/8s of an inch thick.
Anyway, you have to bend plastic, and you want to do it right, so this is the place for you! Now, onward, to the instruction!
Step 1: Prep! Removing Protective Film and Marking the Plastic for Meassurment
When handling sheet plastic, it is always best to keep the protective film on it for as long as possible to avoid scratches. Because we are going to be applying thermal energy to the plastic, you must remove the film. If you do not remove the film, the film will melt to your plastic will be nearly impossible to remove. Remove the film only along the area you will heat bend so that the rest of the plastic stays in good (unscratched) shape.
The easiest way to mark your plastic is to use a sharp knife. Carefully mark the areas you want to bend with a light scratch. This scratch can be buffed out, or will normally just melt back into the plastic during the heat bending process.