Basic Vacuum Forming and Vacuum Machine Building

'What is - and how to vac form? The info is not specific to Classic Cylon Centurions, but SURE can be helpful for them and many, many others projects. Here you'll find various threads with great info from our members for the hobby of costuming.
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Big Al
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 02, 2011 3:59 am

Cylon-Knight wrote:^ wow
I know, cool stuff huh?
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 09, 2011 3:08 am

:cylongold: Volpin DIY Vacuum Form Machine Build


:cylon: Ok it's been awhile since I added to this thread but I found this build while I was searching for Rototcast and Mold building information and I thought it was a great home made machine.

Harrison Krix, a graphic designer and propmaker from Atlanta AKA Volpin Props is a very talented guy who states very clearly he is a hobbyist and does not sell to many of his creations but in my opinion he is every bit as good as a hollywood vetran prop maker. If you look at his links and his flicker account he has built many different props some from video games like the N7 gun from Mass Effect 2 and the two Daft Punk helmets and many more.

I have never seen a build or builds that were so well documented!. The helmet builds he has done are the most intense complicated helmet builds I have ever seen! His photos take you through every step from creating the plugs to the final product!... His Flicker account has over 1800 photos of his builds and all step by step.

I am going to feature him on the Rotocasting thread but while I was searching all of his work I stumbled on his Vacuum Form machine build.

This is a great Machine and is real inexspensive to build and is used in conjuntion with other methods such as Rotocasting to achive the final products.



:cylon: Volpin Props Vacuum Form Machine


:cylon: Budget build mini vacuum-former
June 13, 2010

I have long wanted a vacuum-forming machine of my own, and after scouring tons of resources online, I finally decided to try my hand at it.

[attachment=6]Volpin Machine 1.jpg[/attachment]

My former is a little bit different from others I
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 09, 2011 3:22 am

:cylongold:Volpin Machine Cont.


This is the cobbled-together adapter I
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 09, 2011 3:38 am

:cylongold: Volpin Machine Build Cont. 2




[attachment=6]Volpin Machine 15.jpg[/attachment]

I also stained and sealed certain pieces of the machine to protect them from wear and tear. The platen and frames were stained and sealed, while the oven and support arms got a coat of wood hardener.

[attachment=5]Volpin Machine 16.jpg[/attachment]

For power, I ran a grounded line to a distribution box with its own outlet. The switch here controls the oven, and the outlet is used for the vacuum and heat gun. Don
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 09, 2011 4:01 am

:cylongold: Volpin Machine Build Cont. 3


With that done, it was tine to melt some plastic! I grabbed some random junk from my shop and lined it up. Shown (clockwise) is:

1.A filigree piece from my Hylian Shield build
2.An aluminum block
3.The mold master puck from Chell
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Craigorski » Sat Aug 20, 2011 3:35 am

Nice.. i should show this to my buddies who have been planning a vac table for over a year..slackers!
i have several forms ready for them, but no vac table.

cheers for showing.. much appreciated

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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sat Aug 20, 2011 9:03 am

Craigorski wrote:Nice.. i should show this to my buddies who have been planning a vac table for over a year..slackers!
i have several forms ready for them, but no vac table.

cheers for showing.. much appreciated

Cool ..... :cool: Glad I could help! :salute:
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Tue Aug 23, 2011 8:44 pm

:cylongold:Creating the Original Stormtrooper Armour by Andrew Ainsworth

:cylon: I was trooping around the other forums and found a link to this on TK560. I'm sure the vetran Cylons here have seen this before but the new guy's (like myself) will love it! I know I did :cool:

This guy is the creator and designer of all the screen used Star Wars Armor ... when you watch this guy work it's amazing....He doesn't Frack around! this guy is a master Vacuum Former :cylon:

He also shows you how to make certain parts with free form techniques utilizing the vac machine.

The first video is Andrew creating the the stormtrooper helmet from plug to finish helmet. (Not much talking)
the next two are the complete armor set, Tie Fighter helmet, rebel helmet.

Very cool stuff.
Enjoy.


:cylon: Creating the original Stormtrooper




:cylon: Creating the original Stormtrooper armour




:cylon: Creating the Rebel Troop Helmets




:loveit: I love this quote......


"This plug is made from re-constituted Aloo-mini-um"



UPDATE: 10/26/2011


I started this post by saying that Andrew Ainsworth was the creator of the stormtrooper and I have since seen many threads on other forums that dispute this ......Ainsworth has been battling George Lucas for years over this issue and has in fact lost his case in the U.S. and ordered to pay 20 mil to Lucas for copyright infringement. He did however win his case in the U.K. and is now producing armor and helmets to sell but cannot sell to the US.

The most debated forums on this case are on the RPF on which in fact I have talked with Brian Muir the original Sculptor of Darth Vader ANH, Brian assures me that Ainsworth is a scoundral and that Liz Moore sculpted the original stormtrooper helmet and Brian sculpted the armor, Liz also was the sculptor of C3PO. Brian asserts that Ainsworth was simply a vacuum forming house who was commissioned to pull the many parts needed for the film. Ainsworth claims to be the sculptor and to have the original bucks. Because there are no pics of Liz and Brian sculpting the suites and armor, and Liz Moore has since passed away, Ainsworth has claimed this work as his own.

Brian also told me that the videos were made as evidence for his trial.

You can judge for yourself here: Brian Muir/Ainsworth Thread

Although I have read alot of debate about this, I did not give it much thought untill I read Brian's thread.

Never the less, I will leave the videos because I am not to interested in the politics and my thread is about the tech and skills needed to make armor and I still think the videos are a good demonstration of vacuum forming parts.
Last edited by Big Al on Wed Oct 26, 2011 6:20 pm, edited 1 time in total.
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Thu Sep 01, 2011 11:06 am

:cylongold: ALSA Corp Vacuum Formable Chrome Sheets


:cylon: This disscussion started on another thread here at BYC and it was about another product ALSA makes "Peel and stick chrome film"...so I did a little research (went to their web site) and discovered they make several products for chroming.

Peel and stick film, Spray on chrome paint, Powder coating Chrome, and this one

Formable Chrome Sheeting

The plastic sheet is a laminate of Petg, Chrome (Mylar) and a black ABS backing sheet.

Available in thicknesses of .30 to 1/2 inch

:cylon: Samples of Formable Chrome

[attachment=5]frmblchrm_01.jpg[/attachment]

[attachment=4]frmblchrm_06.jpg[/attachment]

[attachment=3]frmblchrm_11.jpg[/attachment]

[attachment=2]frmblchrm_12.jpg[/attachment]

[attachment=1]frmblchrm_14.jpg[/attachment]

[attachment=0]frmblchrm_15.jpg[/attachment]

You should look at their video demos on their web site as they also make a chrome paint that is awesome!

Here are the specs on the formable chrome

:cylon: Alsa
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Megatron » Sat Nov 19, 2011 9:51 pm

hmm no mention of kydex plastic- its the king of plastic for thermoforming
http://www.kydex.com/technical-data/tec ... riefs.aspx

has some easy to read info on it
http://www.plastics2000.net/kydex
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sat Nov 19, 2011 10:59 pm

Megatron wrote:hmm no mention of kydex plastic- its the king of plastic for thermoforming
http://www.kydex.com/technical-data/tec ... riefs.aspx

has some easy to read info on it
http://www.plastics2000.net/kydex

I have never used it but I think I did mention it early on in the thread when I covered types of plastics...Kydex I believe is used for making form fitting pistol holsters because of it's strength and it can be very ridgid not to mention I think it has a texture of orange peal so when they form holsters they cover it with leather.....I also think you need alot of heat and presure....I covered it just because it is used for forming but mostly here it's home built machines for ABS.

Thanks for the links though everything helps ! :salute:
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Megatron » Sun Nov 20, 2011 7:37 pm

Big Al wrote:
Megatron wrote:hmm no mention of kydex plastic- its the king of plastic for thermoforming
http://www.kydex.com/technical-data/tec ... riefs.aspx

has some easy to read info on it
http://www.plastics2000.net/kydex

I have never used it but I think I did mention it early on in the thread when I covered types of plastics...Kydex I believe is used for making form fitting pistol holsters because of it's strength and it can be very ridgid not to mention I think it has a texture of orange peal so when they form holsters they cover it with leather.....I also think you need alot of heat and presure....I covered it just because it is used for forming but mostly here it's home built machines for ABS.

Thanks for the links though everything helps ! :salute:
it comes in smooth too..
temp for forming is not the much different depending on thickness of the sheeet for ovens 330
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Sun Nov 20, 2011 8:46 pm

Megatron wrote:
Big Al wrote:
Megatron wrote:hmm no mention of kydex plastic- its the king of plastic for thermoforming
http://www.kydex.com/technical-data/tec ... riefs.aspx

has some easy to read info on it
http://www.plastics2000.net/kydex

I have never used it but I think I did mention it early on in the thread when I covered types of plastics...Kydex I believe is used for making form fitting pistol holsters because of it's strength and it can be very ridgid not to mention I think it has a texture of orange peal so when they form holsters they cover it with leather.....I also think you need alot of heat and presure....I covered it just because it is used for forming but mostly here it's home built machines for ABS.

Thanks for the links though everything helps ! :salute:
it comes in smooth too..
temp for forming is not the much different depending on thickness of the sheeet for ovens 330
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Re: Basic Vacuum Forming and Vacuum Machine Building

Post by Big Al » Fri May 04, 2012 1:04 am

:cylongold: 3D Printer for making parts


:cylon: Daniel Goodman | Dec. 22, 2011, 9:22 AM


The Wired Store at Times Square and 42nd St is closing on Saturday, and if you can you should go check it out. If not, don't worry, we got the goods for you right here.

Since 2007, Wired, the Cond
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