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How to Thermaform Plastic

There are a number of techniques that can be used to make a great looking costume. However, sometimes fabric and thread just isn't enough to make an outfit look "just right". In such circumstances, a costumer has to think outside the box, and for a lot of professional costumers, knowing how to thermaform plastic is an invaluable skill. Traditionally used for making armor, or "solid" costume pieces, the process is an easy alternative to hours of casting and sculpting to achieve essentially the same result.

Things You'll Need

  • Stove Top Burner
  • Sheet Plastic
  • Safety Goggles
  • Heavy Gloves
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Instructions

    • 1

      Turn on the burner. Set it to the highest possible setting. When it has heated fully, proceed to step two.

    • 2

      Put on the gloves and pick up a sheet of plastic. Make sure that the plastic has already been cut into a workable size for the costume piece that you happen to be creating.

    • 3

      Put the plastic over the heat. You should hold it roughly 12 inches above the burner. The heat will make the plastic flexible.

    • 4

      Shape your piece. When the plastic has been heated to an appropriate level, use your hands to manipulate the plastic into your desired form.

    • 5

      Retain the shape. The natural properties of the plastic will make it want to revert to its original shape, so apply pressure until it is able to retain your changes without bending/moving on its own.

    • 6

      Allow the piece to cool. This can take quite some time (depending on what type of plastic you use), so don't be too eager, or you could potentially undo all of your hard work by touching it too soon.

    • 7

      Finish and paint the piece.

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