A friend who teaches industrial design at the local university is attempting to find a misplaced book for me on making parts for stage sets made with a "$100 vacuum former" using peg board, a shop vac, and some heat lamps I suspect, ABS plastic, and Lexan are two that I have been told will work, lexan is clear and is often used in place of glass for windows, if you get it thick enough (half inch I think) then it's practically bullet proof!
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