Vacuum Forming Die Material

[bsteinma]

I am working on building an artificial chest cavity for research purposes at work. I believe the best way to do this would be to vacuum form the two halves. I have been interested in making the die myself, but I'm not sure that my idea will work.

I was going to get information from a set of medical images that would allow me to construct the cavity out of layers of structural/insulating foam. After attaching the layers and smoothing the entire thing out I thought I could cut the mold in half and use each as a die for vacuum forming. However, with the heat involved I'm not sure this would work and am looking for input.

The alternative, which would be quicker but likely more expensive, is to use rapid prototyping to make the die out of ABS plastic. That raises the same concerns about the heat involved.

Would either of these materials work as dies for vacuum forming?

Any input is greatly appreciated.

Thanks,
bsteinma

[vigilante212]

I guess it depends on what material your going to use for the form. One way you could do it altohugh it would take more time. Make your foam mold, then form a fiberglass mold around it with a enamel coating on the inside. Then just melt the foam out using acetone and then pour in a good heat resistant compound for your mold. Then pull apart the fiberglass and you have a good mold.

Look on youtube for some 2 part mold how too's.