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Vacuum forming tutorial by DarkAsylumxxx Vacuum forming tutorial by DarkAsylumxxx
By a large amount of request about this process and the interest of how it's done.

Here's the step by step tutorial of vacuum forming a Iron man helmet, ENJOY!!!
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:iconfinaformsora:
finaformsora Featured By Owner Jun 18, 2013  Hobbyist Artisan Crafter
is it possible to make a two part mold for casting say... a keyblade?
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jun 21, 2013
yeah as long as you need a hollow form pretty much vacuum forming is the ideal option.
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:iconc-scharlach-j:
c-SCHARLACH-j Featured By Owner May 27, 2013  Student Artist
great
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:iconbear48:
bear48 Featured By Owner Mar 27, 2013  Professional
very cool
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:iconmrproductionsrd:
MRproductionsRD Featured By Owner Oct 30, 2012  Hobbyist Filmographer
awesome work man!! do you sell this?? if you do , how much??
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Oct 31, 2012
I use too, haven't made in any quite some time not sure of the material cost at the moment the price of oil depends on the prices of plastics required.
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:iconmrproductionsrd:
MRproductionsRD Featured By Owner Oct 29, 2012  Hobbyist Filmographer
jey nice workk man!! dou you sell this???
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:iconwebgrafico:
webgrafico Featured By Owner Sep 17, 2012
wooooooooooowwwwwwwwwwwww!!!!!!!!!
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:iconmasahiiro:
Masahiiro Featured By Owner Jun 6, 2012  Hobbyist Artist
This is so cheating! I like! XD
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:iconvenegal:
Venegal Featured By Owner Sep 16, 2012  Hobbyist Artisan Crafter
Using Pepakura is cheating, THIS is the master stuff.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Aug 15, 2012
I dont think it
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:iconslayer500:
slayer500 Featured By Owner May 13, 2012
how much does it cost to get forming done because i have armour that needs forming
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Aug 15, 2012
depends on the material what type of plastic and how many sheets it takes like 6 runs on the machine for a full iron man suit as an example.
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:iconfrankaster1987:
FRANKASTER1987 Featured By Owner Apr 24, 2012
pretty nice, i love the detail, I'm still struggling with my im helmet,what do you do for getting the eyes holes sucked... in my project the eyes did get that sharp look as yours.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Apr 27, 2012
I made a outer press mold I push into the eyes to compress them deeper and sharper just gotta do it while the plastic is still hot.
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:iconfrankaster1987:
FRANKASTER1987 Featured By Owner May 1, 2012
wow thanks! this will be very useful since i hate how the eye hole loses most of the detail!
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:icondiachikichouhin:
DiachiKichouhin Featured By Owner Nov 11, 2011
crazy nuts! i don't have any equipment like that. wish i did. but i have no idea where i would stick it.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Nov 12, 2011
Well alot a universities have vacuum forming machines on hand that's were the machine I use came from was a 40 year old broken machine that was given to my grandfather and a few years back I found it in storage fixed it up and started using it.
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:icondeceptivealias:
DeceptiveAlias Featured By Owner Sep 12, 2011  Student General Artist
awesome talent/skills man!
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:iconletum-adveho:
Letum-Adveho Featured By Owner Jan 20, 2011  Hobbyist Traditional Artist
Hey this is Letum from the rpf.

So I have a question, what was the solvent that you used to "weld" the parts together? Im having a serious issue with this lol.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jan 21, 2011
SOrry for the late reply, you can use IPS weldon #3 [link] most plastic or hobby shops sell it it will work on arcylic strylene, ABS plexi glass, and even Lexan and a few other polymors even butadiene.


You can also use scrap plastics in a glass jar add the #3 and let it melt over nite and make a reinforcing plastic paste you can use to fill in gaps or reinforce welds but becareful not to use it heavy but in layers still otherwise it can distort shells if it's too thick cause it's still a solvent.
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:iconletum-adveho:
Letum-Adveho Featured By Owner Jan 22, 2011  Hobbyist Traditional Artist
Thank you so much!

This helps me a lot. Ive been contemplating on what to use to splice pieces together. This will work perfect! ^^
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jan 23, 2011
sorry if I reply late especially on the RPF I don't do much lurking there about all I do is post my WIP and answer questions and post advice but some people have took it the wrong way thus I stay out of other peoples threads for the most part anymore so generally via Email or you can post here to get a hold of me faster I was planning bullet points and notes for your thread cause I noticed a few comments are some what miss leading and when doing plastic work some rules need to be set in stone if you want to insure high quality, you start using the wrong welding solvents or materials and seems will start to crack and other worse things so I'll try to get that put together for every one soon.
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:iconletum-adveho:
Letum-Adveho Featured By Owner Jan 27, 2011  Hobbyist Traditional Artist
That would be really awesome.

Feel free to post in my thread ANYTIME you want! ^^ Im an ass, not much gets me upset lol.

I really appreciate your help though. When it comes to this plastic, im going to need the most help I can get.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jan 28, 2011
No problem, it's was mostly the Ironman builders like TMP that started the biggest problems but I'll still post when I have time here and there and I have something construction to add otherwise it just seems to bring me drama anymore.
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:iconmhrithikun:
mhrithikun Featured By Owner Nov 20, 2010  Professional Traditional Artist
..u r a genius......please.....i wanna work wid u..............is it possible???
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Nov 20, 2010
How do you mean?
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:iconmhrithikun:
mhrithikun Featured By Owner Aug 31, 2011  Professional Traditional Artist
it means make me ur assistent............:-]
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:iconever-smiling:
Ever-smiling Featured By Owner Nov 17, 2010  Hobbyist Artisan Crafter
Totally amazing!!!!
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Nov 17, 2010
it's a cool process for light weight armor parts atleast.
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:iconreikainaric:
ReiKainaric Featured By Owner Oct 29, 2010  Student Digital Artist
Isn't it hard to make the model before you vacuum it =/?
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Oct 29, 2010
well, after so many years of building and constructing using this method I think it's easy anough it's cleaner and more professional I think cause using the hard builds things are far more symmetrical smoother and far more durable.
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:iconreikainaric:
ReiKainaric Featured By Owner Oct 28, 2010  Student Digital Artist
Doesn't it feel weird to have plastic on your head? Or you put something under it? How solid is it? Like if I hit my head again the wall or something on accident. I know its 16th thousands thickness but how hard is that. Can this be used for armor? (if not answered already) If so how in armor form can it be solid and not all soft and plasticky like?
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Oct 28, 2010
Well it's atleast 3-4 times stronger then fiber glass more flex but it's a good idea to add foam padding to steady the plastic to your headas far as armor better off with ABS plastic over styrene if you plan fighting and combat as it is more flexible and stress resistant, different plastic materials very by flex or strength the white styrene plastic is a high impact polymor and a few bumps and hits wont crack or do much but a heavy high pactic hit can crack the shell it tends rip under heavy stress rather then chip or shatter not that fragile compared to fiber glass and crap resins.
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:iconreikainaric:
ReiKainaric Featured By Owner Oct 4, 2010  Student Digital Artist
I don't understand what you used for the mold. Can you elaborate? How did you make it so smooth? How thick was your plastic? How hard is it? And what kind of specialized solvent? Sorry if I'm asking too many questions, I'm a beginner and trying to make a helmet myself but of a different character plus young so can't understand complicated stuff ._.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Oct 5, 2010
No problem,I used a recast 10 pound foam mask head and sculpted the helmet over the mask head with AVES epoxy sculpt smoothed with alot ofwater and sanding cut up the mold and added 3 quarter inch blocks to rise them up to keep from the edges flaring oddly were the plastic cools faster.

I used 16th thousands thinckness and weldon 3 is about the best solvent bonder for HIP's.
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:iconreikainaric:
ReiKainaric Featured By Owner Oct 5, 2010  Student Digital Artist
Where do you buy these materials? Only place I know is Home Depot.
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Oct 5, 2010
you need to find a local polymer supplier but you can get styrene from some hobby shops aswell.
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:iconkreepingspawn:
KreepingSpawn Featured By Owner Sep 19, 2010  Professional Digital Artist
that is so cool! and so out of my league. ;p
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Sep 19, 2010
Well get money invested in the tools and I think it does help, I mean think about it you can't butter toast with a tooth pick now can you.
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:iconkreepingspawn:
KreepingSpawn Featured By Owner Sep 20, 2010  Professional Digital Artist
true true. ;)
yes, i'm slowly, very slowly, building my resources. :evillaugh:
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Sep 20, 2010
That's good, it's all worth the time and money when you see the final out come.
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:iconkreepingspawn:
KreepingSpawn Featured By Owner Sep 21, 2010  Professional Digital Artist
i can see! :D
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:iconsmallrinilady:
smallrinilady Featured By Owner Jun 23, 2010
so um, what are the chances that people have a vacumn thing in their own cosplay studio?
how did you come across one?
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jun 24, 2010
I'm not sure how many people own one few people build them out of old junk but not going to get a high quality form that way, this former was built in a university like 45 years ago my grandfather got it from them the thing was broken pulled it out of storage a few years back fixed it and modified it and that's about it, you can build one but you would be best to look up a few books on it for the best designs nothing good on the internet about vacuum formers.
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:iconthehiddenwind:
TheHiddenWind Featured By Owner Jun 13, 2010
Can I ask how you joined the pieces together?

The result looks amazing btw, but I'm sure you don't need me tell you that xD
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:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Jun 15, 2010
weld-on #3 plastic solvent
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:iconincompleteme:
IncompleteMe Featured By Owner Mar 30, 2010  Student Traditional Artist
This is a great insight into your process!
Reply
:icondarkasylumxxx:
DarkAsylumxxx Featured By Owner Mar 30, 2010
It's one process I like to use fpr durible light weight armor, but building the original molds is the tricky part.
Reply
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