1) No Pthalates in styrene. the most common choice for vacuum forming by the hobby builder.
2) Low levels of styrene occur naturally in plants as well as a variety of foods such as fruits, vegetables, nuts. [
care of Wikipedia]
3) Phthalates are used, and have been in the US since before the 1950's, in a large variety of products, from
enteric coatings of pharmaceutical pills to
viscosity control agents, gelling agents, film formers,
stabilizers,
dispersants,
lubricants, binders,
emulsifying agents, and suspending agents. [
care of Wikipedia]
4)In '08 the US ordered a specific study regarding the effects of phalates on Humans. Until the vast majority of actual studies including those all over the world that produced results, were on rodents and even then, only after very high doses, was their any impact. At this point all concerns regarding human exposure have been theoretical and unproven. The combination of Pthalates used in PVC were thought to be carinogenic, at high levels, and in the end the research determined that this effect was found only in rats.
If you don't have children in the house. And arent licking the inside of your oven between pulls, and don't decide to go professional and use the oven every day. You will be just fine.
Cheers,
JM