Re: Stewart

Posted by HH56 On 2023/2/6 19:25:59

Looking forward to seeing your results.

Since you have so many sharp 90 degree bends both in the middle and on the sides the ABS will need to be quickly placed and formed before the stuff gets too hard to do a good bend yet also held while it completely cools. It will be worse with any little segments resulting from slits needed to avoid tears or wrinkles in the material.

To help the situation you could make two secondary molds for each size out of 1/2" plywood or such. It would need to be slightly larger in width than the pattern side with a gap only on the narrow sides roughly double the thickness of the ABS on each side. Make it so you can place the hot ABS over the actual pattern side and then after starting the bends with your hand gently push the larger mold on top to sort of help form and hold the ABS to the pattern. Once formed you can leave it like that while the ABS cools enough to retain the shape. Gently rounded edges or corners on both sides of the molds will help the ABS form without tearing.

How are you going to join the halves. If you plan to overlap the full sides then making one of the secondary molds slightly wider and adding a thin piece of cardboard or such the same thickness as the ABS to the sides of the pattern mold before forming the second half might provide a kind of slip fit when they are joined.

I found it hard to handle the ABS when hot and you almost need a flat solid metal surface for it to lay on while it heats and then help you carry it to the project so it does not droop. My kitchen oven and an old cookie sheet worked well but your wife may have other ideas so good luck there.