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Coating the PLA visor buck in a layer of bondo will help prevent the buck from melting when you go to vacuum form. Adds a little bit more work to do, but also adds a layer of protection when it's done.
Thank you, I tried adding bondo but I don't know why but it keeps flaking off. Im going to just reinforce the back of it with it and see if that works. Also the bondo im using is called plastic metal, is that the right stuff?
 
Sadly, the mold was a bust. The 2 types of silicone didn't fuse after all so I had to scrap it all. And while trying to get the silicone and fiberglass off the helmet split in 2 places. After fixing it I got it all painted, even after the tape ripped most of the paint off... but on the plus side the hip plates were finished without disaster haha. Now all I need is the visor and sword!
 

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