You do need a vacuum, or you won't be able to get the warmed sheet to conform to the mold. You'll end up molding all of the air pockets.
Building the vacuum table itself is really easy, especially if you don't need rail guides or anything. You can make one out of 2x4s, pegboard, drywall screws, and caulking compound.
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Originally Posted by cfg83
Question: Would I have to worry about "outgassing" (not exactly the right word) as the plastic heats up?
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If you're doing it right, you won't be heating the plastic enough for it to be combusting or producing fumes. You're heating it to the level of thermoforming, the same temperatures that the manufacturer uses to injection, blow, or vacuum mold it to the desired shape.