Sheets of polystyrene plastic

The problem is, does anyone know where to buy sheets of polystyrene plastic for vacuum moulding in the Sydney area? Alternatively, does anyone know of any other plastic used instead of polystyrene that may be more easily accessable (effectswizard, this may be your area).

I've done a ring around and I can't find anyone who sells it.

I have no idea where to find the plastic, but you might want to ask somebody in construction or something.

You could also use a search engine, but you've probly already done that.

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http://www.jacksloan.com

They actually made some props for some Star Wars movies!

Their site is located here:http://www.eps.i12.com/

I also found another site:http://www.thomasregional.com/scal/ips

AND
http://www.plasticsnet.com/

Hope some of those help.

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http://www.jacksloan.com

Thanks for the links, but I'm looking for Australian suppliers (Sydney) and these are all links to the US and UK with no O/S distribution. Thank you for passing on the links though.

You know, it seems like getting any raw materials in Aust is difficult. When I first bought resin, it was a nightmare.

Is he talking about US imperial? What would be the metric equivalent, or does he mean metric 0.08mm. That's awfully thin for a mask.

I hope this helps. If you can give me an idea on the objects's size, I can help a little more. Just email me.

Good luck!!

It seems to be a few inches deep. I guess I'd need about a 0.5mm on this?

The one I bought wasn't that expensive. The only thing is, the ear protectors are foam, not plastic.
It's an X-Fire too.

Oh, how many are you planning to make? If you need to make like ten or something, then I can see why you want to vaccu.

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http://www.jacksloan.com

I even went as far as to offer her some space my garage as a trade. That didn't help. So many obstacles...

I do this stuff just about every day, so let me know if you need more help.

polyethylene sheet 2000mm x 1000mm is $AUS70 + TAX
polystyrene sheet 2000mm x 1000mm is $AUS12 + TAX

I think polystyrene is the way to go for the moment till I learn the craft a bit. Thank you everyone for your tips and advice. Now to get that space in the kitchen....

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Sausage's Lounge Area

Good luck, and yell if you need any help.

i've used it for understructures in animatronics too...i like it better then ps since its clear and strong, just my 2¢

later
Tom

i just noticed your statement about making "original" stuff, last time i checked copying something isnt original...are you making something similar?

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http://www.jacksloan.com

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I was normal once..... I didn't like it.
pray for mojo
you sold me queer giraffes!
check my site http://www.novicepictures.com

The cost of a good vacuum form machine can run into the many multiple thousands of dollars. HOWEVER, you can gather reasonable components and make one that is really quite good for next to nothing. The heat source is the main issue and then whatever you use to "draw down" the plastic after it's been heated and placed over the mold on the vacuum table or box (whatever size you decide to build). It usually takes a good shop vac to pull it down tight enough to get excellent detail and really should be a commercial vaccuum pump. I have a 3/4 horsepower compressor that doubles as a vacuum compressor. They say to do it in two stages - first pulling it down with a shop vac as far as it will go. And when that has reached the maximum draw the vacuum pump takes over and draws it WAY tight into the mold to get the best detail. It requires almost 30 inces of mercury (the measurement for vacuum) to draw that tight. Shop vacs can do about anywhere from 24 - 27 or 28.5 or so. That isn't too bad. As the maximum you ever draw is 30 inches I believe it is. Somewhere I understand that vacuum can't go anymore than that - it can just go longer but will never exceed that measurement. I don't really understand physics but it's something like that. I have two started and ultimately I'll have about $100 or so apiece in them. The small ones even run about $450 if you buy one already made.

I hope this helps.

I'm just looking at the painball mask as a bit of inspiration. The actual masks and suits will be original. When I went paintballing once, I thought the masks were really cool. But I wouldn't want anyone recognising a paintball mask in the film.

It doesn't matter if the masks break during filming. There'll be a few made and I'll just make another.

i have actually seen some of those paintball masks in movies, i always laugh when i do.

well, good luck w the VF and the masks, let us see some pics when you finally get them done

Well I have one on polyester resins but I'll post that out in the main area.

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fxscooby
DreamFX

pTgR

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"Every normal man must be tempted at times to spit on his hands, hoist the black flag, and begin slitting throats."
H.L. Mencken

a real vacuform (at least the ones i've used) has the heating element on the top facing downwards, directly over the vacuum table portion, when the plastic's hot enough you just pull the holding frame and the plastic down onto your form so you dont really have to worry about burning yourself, unless of course you stick your hands into the hot plastic, or heating element, but thats about as dumb as sticking your hand into an oven

The $100 for the vacuum form machines are for both of them HOWEVER, that is for the forming box, the heater and small parts only not the vacuum source.. I got all the parts for the heater (the electric grill) from Sunbeam directly for $25 bucks. Two sets of everything (I'm making one for a friend of mine). But all the other small parts as well as the lumber and such barely added up to the $100 bucks. That cost DOESN'T include the vacuum. I already have two other sources I planned to use. One, is an old bike pump redone in "reverse" to create a vaccum pump instead of an air pump. It will pull all the vacuum you'd need to do a good job. The other is a nearly $300 compressor I have that doubles as a vacuum pump (3/4 HP) and therefore I didn't need the vacuum cleaners. I have a shop vac that will do the stage one pull and then when that does all it can, the secondary source - the vacuum pump - kicks in and will finish the pull as tight as it could get before the plastic gets too cool. Mine uses the Sunbeam electric grill which is still available at Wal-Mart I think for like $39 bucks and will do anything up to about 9" X 12" or smaller. Anything larger you'd need a bigger machine and heat source. But the $100 is "to date" cost and I know it will come to more than that when it's all built. And if I then figure in the cost of the things I already have, then that will make a difference.

But they're so easy to build and use except for having the heat source big enough to do what you need. The guy who wrote the book on it recommends using a machine as close to your heat source as you can so you don't waste time getting the plastic to the forming table and getting your pieces made.

Good luck!!

FXMan

well, i went out and bought one of those 4 1/4 Hp shop vacs, hooked it up to the table i was building, good news, its completely sealed bad news is my stupid frames i made have plastic corner connectors, so i have to rebuild them (i am really stupid and forgetful while walking around my local 24-7 home depot buying parts for this on a whim)

but anyway, i have all the parts, i know that the table itself will work, now all i have to do is whip up some holding frames and test this bugger out!

wish me luck.

ivan, do you build a lot of stuff? or are you more of a CGI man? if you build models, you can cut down your time if you have anything that repeats a lot, small detailed panels, you can actually make model kits with one, plus armor and other cool stuff.

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I was normal once..... I didn't like it.
pray for mojo
you sold me queer giraffes!
check my site http://www.novicepictures.com

gimme a day or two

the top and bottom are the pieces that were vacuformed over an acrylic and bondo form, the fins and scopes are acrylic scrap, and the tower is 2 tubes for the ends, some styrene for the sides and top, add some "borrowed" decals, model parts, and an airbrused paintjob and voila submarine de jour

not the greatest job, but i think it looks pretty good...except for the crappy "setting"

i got a hunk of .080" HIPS (about 3/32 inch High Impact PolyStyrene) from work to test out my awesome building skills. on a simple curved surface i tested it on, and only allowing the plastic to droop about 2-3 inches i took it out, put it on the machine and hit the vacuum. my mom was holding the "table" and when the plastic popped it scared the hell out of her...but the important thing is that it worked, it worked on a thicker piece of plastic that i would need and my plastic corner pieces didnt show any sign of heat damage, let alone melting (which i was really concerned about)

anyway, i probably spent a total of $20 for the table materials, plus the shop vac...if you're interested in the plans, http://www.likeastory.com/boards/Forum9/HTML/000799.html it has the source for my plans...i'll post a pic of this first test piece once i get a pic of it if anyone cares

later
Tom

It doesn't really seem that hard to build.

How long did it take you?

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JACKSLOAN.COM

the "directions" i went by said to rivet a piece of window screen to the top of the table, but they also said to use 1/4" holes...i drilled 3/16" and with the thicker plastic and shorter heating time it seems ok, i also spaced the holes closer and added more of them then in the "directions"...on the next table i will use 1/8 (or smaller) and probably space them 1/2" apart.

on thinner plastic i would recommend trying the screen idea , but maybe inside the top pan, i dont know how it would work.

this is pretty much all it took:
2 11"x17" aluminum cookie sheets
2 feet of 1" PVC pipe
1 11/4" sump pump check vavle
1 11/4" threaded pipe flange (either PVC or metal)
1 tube silicone sealant
window screen frame kit (2 pieces of stock and 2 sets of corner pieces)
a couple inches of elastic
paper clamps
assorted nuts, bolts and pop rivets
a shopvac

total cost for materials alone roughly $25.00, plus the shop vac($60.00)=$85.00 and many of these things give you way more then you need, you only use a fraction of the tube of silicone, not all of the screen stock, so you could build a small machine for less money. which is what i think i'm going to do next, or maybe a vacuum chamber for silicone degassing....

later
TOm

Cool. Did you use the directions from the DH2 site or some of your own?

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Visit
JACKSLOAN.COM

basically i built the one in there, but "tweaked" it to my personal likes. nothing major, i think i mentioned everything i did differently in the last post

well if the holes are small enough that helps out, but the plans call for the screen (see last post)to be rivited to the top to prevent this. if this is going to be your first attempt, i'd recommend using the screen(window screen, the kind to prevent bugs from getting in your house)i just didnt feel like messing with it.

Does Fine Scale Modeler have a site where I might be able to get the plans?

Also, would a store such as Lowe's have the 0.080 Polystyrene?

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Visit
JACKSLOAN.COM

just go to the order back issues section, they have the magazine for $4.50

and i dont know if Lowe's would have the styrene, you might want to check at hobby shops or model stores

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Visit
JACKSLOAN.COM

just curious, but always willing to help out if you get stuck

later
Tom

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