[justpassntime]

Originally Posted by MechEngVT

ABS plastic isn't very exotic, is very durable, and it thermo-forms. A lot of industrial and automotive parts are vacuum-formed from ABS. I've heard that ABS is harder to heat to a workable state than some other plastics like polystyrene or polyethylene. Keep in mind you'll want to work with thin sheet as opposed to blocks, but not so thin that as you heat and work the plastic it'll stretch/tear. You'll probably want to stay with .090" or 1/8" and above, but 1/4" is probably too thick to work by hand.

For availability you might have the best luck with polyethylene. You should be able to order sheets of many thicknesses of HDPE from industrial supply catalogs or possibly local stores, but I wouldn't hold my breath for Home Depot or Lowe's to have it.

Thanks for the info