I build a thermoforming box to copy a 3L Jack Daniels Bottle. Why? The plan is to make a Jack Daniels Mirror Ball Bottle out of polystyrene.
Thermoforming is a manufacturing process where a plastic sheet is heated to a pliable forming temperature, formed to a specific shape in a mold, and trimmed to create a usable product. The sheet, or "film" when referring to thinner gauges and certain material types, is heated in an oven to a high-enough temperature that permits it to be stretched into or onto a mold and cooled to a finished shape. Its simplified version is vacuum forming. So says Wikipedia. To get the polystyrene smoothly, 4000 Watts (2 Table Barbecues) were needed; placed in a box made of OSB.
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