In this tutorial we will show you how to make a simple mask using the thermoforming technique.
The full proces can be accomplished using the standart equipment you can find in your workshop.
Step 1: Materials & Equipment
- Woodplate 600 x 400 - width 30
- panel saw
PolyUrethaan foam sculpting
- PolyUrethaan foam
- PolyStyreen plate
- vacuum machine
Step 2: The Base
1. Trim a plate to a size favorable to your vacuum machine.
2. Trim 4 planks to the length of the plate x 30 width.
3. Glue the planks to the plate.
Step 3: The Holes
When you have finished your basis you can sart drilling holes so the air can escape trough the foam.
Step 4: Contour Holes
Drill small holes fitting to the contour of the total foam size so the PS encloses to the foam mold.
Step 5: Finishing the Base
Cut the edges of the base in a 45° angle.
Step 6: PU Foam Mold
Trim the foam to the right size 15 x 25 x 10 with a belt saw for perfection. BE CAREFUL
Step 7: Sculpturing
Use the files to give your foam the rough shape of your mold.
Step 8: Finishing the Mold
Use a fine grain sandpaper to make your mold as smooth as possible.
Step 9: Vacuum Step 1
Put the mold on the base and place them both in the vacuum machine.
Step 10: Vacuum Step 2
Preheat the PolyStyreen sheet until it reaches the plastic shape
Step 11: Vacuum Step 3
Now use the vacuum machine. If you don't know how, don't hesitate ask for assistance. BE CAREFUL
Step 12: Trimming the Product
When the PS is cooled down, you can start cutting it out to the s
Step 13: The Finishing Touch
Now you have a roughly cut-out shape you can fin
Step 14: Test the Product