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Before vacuum-forming polycarbonate (Lex**) you should soak it at about 190 F for 8 hours to drive the moisture out, lest you get steam bubbles. Acrylic is still used on racing cars. It is on the brittle side, but is manageable. Uvex is probably the best for cheap and tough with easy formability.
For a simple shape like moon covers, you can use free-blowing or even sagging. You can also use a male mold, and drape the hot plastic over it, smoothing it with cotton gloves or rags.
Heat guns are good for controlled bulges; bad for even heating. Ovens can be uneven too - you might want to use some tricks to minimize radiant variations and circulate the air.
Unless you see smoke, the fumes are negligible - anyone worried about their kitchen oven could run it to a higher temperature, empty, to volatize any residuals.
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