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To vacuum form polycarbonate without getting bubbles, you have to soak it at 90 C (190 F) for many hours to drive the moisture out. You can do that with an improvised oven using a heater and a good fan to get sheets ready for extensive forming, or just use plexiglas, which is much easier to keep polished.
You can make straight or moderately curved cuts in 1/8" polycarbonate or other plastic sheets by scoring with a sharp blade, and then bending to open the score and re-scoring a few times until the sheet breaks.
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