That armor looks great!
I've got a small question. The parts are vacu-formed, right?
what is the perfect thickness of styrene or HIPS sheets for vacuum-forming?
So that it has enough details but is also strong enough, especially for helmets?
regards
Tom
Hi Tom,
You can get a huge range of opinions on this forum over what is the best material for vacuforming or what is the best thickness!
The styrene used for the original troopers was 0.06 or 1/16". It is a thinner guage but also picks up great detail, because the thicker plastic you use the less detail you get (more soft, i.e., less sharp). In my opinion the helmet doesn't experience much stress, not like the armor, and is perfectly good in that gauge. A 0.06 pull will get thinner in the undercut areas, particularly on the bottom sides of the tube shape running around the head opening at the bottom of the helmet, and is subject to splits there at that gauge, but HIPS is easily repaired and the rubber neck guard keeps things together anyways. On the dome, faceplate, and sides at that gauge, the helmet is surprisingly sturdy. If you want armor just for display or to wear once and a while than 0.06 should be fine. Obviously, the thicker the gauge, the more $$$!
Another common thickness for both HIPS and ABS is 0.08 or 1/12". Some Troopers will get the helmet in 0.06 to get the best detail and then the armor in 0.08 for more durability in trooping. Trooper armor is also made, although less commonly I think, in 0.10 (1/10") and 0.125 ("1/8"). 0.125 HIPS is supposed to be very strong, but I'm not sure how much detail is lost at that gauge (as I don't have anything in that gauge). I've never heard of any vacuformed trooper armor thicker than 1/8", but I'm sure somebody has done it!