As you ll need to put the plastic sheet into the oven this is your size limitation.
Diy plastic sheet molding.
Create high performance plastic parts.
The example here is the outside of a mold but it can work inside too.
Remove the excess water by squeezing the sheets over the bowl.
Create a durable mother shell.
Measure the inside of your oven.
Layer the sheets on top of eachother.
Each sheet should be 6 inches longer than the mold.
Have a mold ready to use.
Dip the sheets in bowl filled with room temperature water for 1 second.
Cut 4 to 6 sheets of plasters.
For vex robotics teams hobby diy industrial crafts.
Polycarbonate clear plastic sheet 12 x 24 x 0 0625 1 16 3 pack shatter resistant easier to cut bend mold than plexiglass.