Moldable plastic sheet ?

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stevewestern

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A slightly odd request - I want to cut and bend to shape some black plastic sheet, about 2mm thick, to make a sunshield for a sat nav amongst other things. Needs to be able to hold it's shape once molded, and I have a heat gun to soften it, which I guess is the way it'll need to be done. It must then remain vaguely pliable, so not something that will shatter.
Does anyone know what I should be looking for or even better who might sell me some ?
I'm only after a few small pieces, maybe 2 or 3 at about 300mmx 300mm maximum.
Thanks for sharing your wisdom !
 
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AFAIK

You need a plastic that is amenable to thermoforming.....................i think I recall that acrylic is one such plastic.

Ideally you need to have a thin and directed heat and a former to bend/shape it against. If you can find in your area a plastics fabrication company that make retail display cases (products) they may have some offcuts(?) and perhaps even give you some pointers as to how to handle the material(s).

HTH :) perhaps?

NB most large scale thermoforming is done using heated jigs/forms and vacumm moulding machines........................though yonks ago I recall visiting one plant where they made margarine pots and though not acrylic the the press 'formed' hundreds in one pass and the floor shook from the impact of each stroke of the machinery.
 
Not quite what you're looking for but what about starting with something like a roller paint tray like this

They can be cut easy and with a soldering iron you can 'weld' pieces together. I've used them in the past for one or two jobs, plastic repairs, ect
 
Box Brownie said:
AFAIK

You need a plastic that is amenable to thermoforming.....................i think I recall that acrylic is one such plastic.

Ideally you need to have a thin and directed heat and a former to bend/shape it against. If you can find in your area a plastics fabrication company that make retail display cases (products) they may have some offcuts(?) and perhaps even give you some pointers as to how to handle the material(s).

HTH :) perhaps?

NB most large scale thermoforming is done using heated jigs/forms and vacumm moulding machines........................though yonks ago I recall visiting one plant where they made margarine pots and though not acrylic the the press 'formed' hundreds in one pass and the floor shook from the impact of each stroke of the machinery.
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Phil-D said:
Not quite what you're looking for but what about starting with something like a roller paint tray like this

They can be cut easy and with a soldering iron you can 'weld' pieces together. I've used them in the past for one or two jobs, plastic repairs, ect
Click to expand...
Thank you both - thermoforming is the word I was looking for, and we do have a place nearby that does plastic fabrications etc so I'll pay them a visit.
 
Kydex?

Relatively cheap, easily available in lots of colours including black :)
 
Would something like this work.
pollyplastics.com/products/moldable-plastic-sheets
 
Steep said:
Kydex?

Relatively cheap, easily available in lots of colours including black :)
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I'd never heard of it but have ordered some, thanks!
tarric said:
Would something like this work.
pollyplastics.com/products/moldable-plastic-sheets
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That's one of the first things I found, but I didn't manage to find anyone selling it in the UK.. :(
Thank you both for your help as well..
 
I've messed about with kydex a few times and it's very easy to use, you can score it and snap it to size when cold.
If you have a specific shape in mind you just bend it while it's hot and hold it in place till it cools, if it's wrong then just heat it up and it returns to it's flat form.

Don't overheat it if the surface finish is important as it can go shiny in patches.
To get a sharp 90deg angle I trap it between two bits of wood and a flat surface, makes a good angle and saves burned fingers.
Heat it on a flat surface on the hob or in the oven and use a hot air gun to reheat bits that need adjusting.
 
Steep said:
I've messed about with kydex a few times and it's very easy to use, you can score it and snap it to size when cold.
If you have a specific shape in mind you just bend it while it's hot and hold it in place till it cools, if it's wrong then just heat it up and it returns to it's flat form.

Don't overheat it if the surface finish is important as it can go shiny in patches.
To get a sharp 90deg angle I trap it between two bits of wood and a flat surface, makes a good angle and saves burned fingers.
Heat it on a flat surface on the hob or in the oven and use a hot air gun to reheat bits that need adjusting.
Click to expand...
Brilliant, many thanks for taking the time to help like this, very much appreciated!
 
Where did you end up getting the Kydex from, Steve? Looks like what I could do with to make a cover for something on a bike. Problem is, I need a bigger bit than appears to be available from Amazon... Could do with closer to A3 than A4.
 
Nod said:
Where did you end up getting the Kydex from, Steve? Looks like what I could do with to make a cover for something on a bike. Problem is, I need a bigger bit than appears to be available from Amazon... Could do with closer to A3 than A4.
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These people Mr Nod - https://www.ebay.co.uk/itm/2-mm-A4-...-/360812838219?_trksid=p2349624.m46890.l49286
I didn't even look for bigger bits as the first thing I want to make is a sunshield for my satnav. Once I've got my head around it I may make a few more things like a rear hugger so should you find anything bigger then please let me know!
 
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Will do. Main problem is that I trust e-bay as far as I can throw a Deltic Locomotive so my options are a bit limited. I'll do a bit more research an contact a couple of the bigger suppliers and see what they can do. TBH, I wish I had saved some of the dead panels from a Landy that Dad and I restored - a sheet of Duralumin would be ideal, if a bit harder to work with.
 
Bookmarked for further research! Thanks for the link, Alan. Might be a bit flimsy for what I want/need it for but probably worth a play.
 
Sounds like you are sorted now but an alternative would be to use something like woven carbon fibre fabric and resin/epoxy, loads of videos on youtube about that sort of thing.
 
Thanks for the suggestion. Used to work with GRP and to do what I want, I'd need to make a male buck then make a mould from that before making the final part. Great if I wanted to make several of them but not ideal for a one off!
 
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