Take a thin sheet of plastic, heat it up, suck the plastic onto a form, and you’re got Vacuum Forming! This process has been used for costume making in the film industry for ages, like for the Stormtrooper armor. Learn how to make your own vacuum forming machine and use the process for props and cosplay in our collection of videos below. For armor pieces, we use thin plastic sheets of Styrene. For transparent visors, we use PETG plastic. The thinner the plastic, the more detail is captured in the vacuform pull.
More Vacuum Forming Videos:
When a Mythbuster issues you a challenge, you rise to the occasion! Adam Savage needed a pair of visors for his ACES space suit costume for his NYCC 2018 incognito costume. Bill and Britt got to work using their brand new vacuum forming machine.
Bill shows you how to make a replica tube to house your very own Venom Symbiote – with a cool twist!
Large vacuum formers are super awesome, but can’t just be purchased like other equipment. Bill teaches you how to make your very own large vacuum former using materials from the hardware store!
A real, metal plated chrome finish can be an expensive process for prop making. In this tutorial, Bill shows how to achieve a faux chrome metal finish using paints and an airbrush.
Britt shows you how she turned the Sweeper Bot’s robot head design into a wearable helmet. The first step was vacuum forming a visor with PET-G plastic, then tinting the visor blue. The helmet was crafted from EVA foam, leaving room for all the cool electronics.
It’s Commander Holly Conrad’s Helmet! Britt shows you how she 3D models, prints, assembles, and paints the helmet. Plus, vacuum-forms the visor!
Bill bumbles his way through some vacuum forming failures and experiments. We all have a good laugh and learn something!
Bill shows you how to custom tint a PETG plastic visor for your costume!
In this episode of Prop: 3D, Bill shows you how to model and print a visor as well as how to mold and cast a durable vacuum forming buck!
Bill shows you how to quickly make a vacuum forming machine from cheap hardware store supplies.
How I made Risty’s Spiked Mace & Shield prop replica weapons from Queen’s Blade.