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There is some development going on at OSE on this as well, so feel free to look there;
Another Idea of mine was to take the thicker sheets produced by the sheet press, and let them “simmer” on a large griddle to alow them to heat treat (for more strength + transparency) and for the sheet to be thinner.
Not exactly sure if it is the same as thermoforming or not, but vacuum forming is very easy to do (assuming we can produce thin enough sheets of plastic), so that may be good to pursue.
Is it open source?
Piping is made by extrusion blow molding or EBM
We may be able to modify the extrusion machine (especially the new one) to do this.
I have suggested we develop this, but so far not much work has been done on it.
Your other option would be to 3D Print everything. You may get some layer lines, but this is doable. Open Source Ecology has done some work on this. The one downside is it will require quite a bit of kit (shredder, filament maker, 3d printer, etc).
Anywho, that’s all I really know so hope I helped!
So basically (non woven (ie solid sheet) plastic textiles? Sounds good.
I think the three options for attachment of seams are sewing (with a sewing machine etc), thermal welding (with a heat gun), or ultrasonic welding (this is done for competative swiming “tech suits” https://en.wikipedia.org/wiki/High-technology_swimwear_fabric)
So i’d say focus on the fabric sheet producing device as that is the real hurdle here.
So just as a warning to others, call this material Foamed Polystyrene (or Expanded Polystyrene Foam (EPS) if you want to get REALLY technical). This is because Styrofoam is copyrighted and this can possibly get you in trouble if you use their “property” etc.
Hope thhis helps!