Thermoforming Instruktable

Introduction: Thermoforming Instruktable

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.

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Step 1: Materials & Equipment


- Woodplate 600 x 400 - width 30

- panel saw

- Woodglue

PolyUrethaan foam sculpting

- PolyUrethaan foam

- Sandpaper

- file


- PolyStyreen plate

- vacuum machine

- Ductape

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


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    5 years ago on Introduction

    That turned out looking great! I've always wanted to do something with thermoforming. Thanks for sharing and being a part of the community!