Vacuum Forming: My first experiences with GaitoFace

Yesterday I had my first experiences with vacuum forming. For the project "GaitoFace" I need a head, which can be projected from the inside with a beamer.

The fact that the material has to be smooth and semitransparent doesn't work so well with the 3d printer. But for the necessary form you can use the 3D printer perfectly.

First I created the 3D model in OpenScad:

Since the head should be life-size, the object hardly fits into the installation space of the Ultimaker 2:


Here the foil made of translucent polypropylene is already clamped into the aluminium frame:


The 3D model on the box that is already connected to the vacuum cleaner:


The foil is heated to 170 degrees in the oven and then quickly press the box:

Worked out great - I now have a thin film in the desired shape:

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