Just an idea - maybe this is for the vacu-formers out there.
According to this, the properties of forming polycarbonate sheets (lexan) is not too different than ABS. I think it cools quicker, but that shouldn't pose much of a problem.
My thought is this - create a mold for the visor, possibly even the double visor, and form the polycarbonate over it. That way you get a more 'bubble' visor than using motorcycle visors. Downside is that as far as I can tell it only comes in clear. But the price is really good - a 4ft by 4ft sheet is only $25, and I think you could probably get about 4 visors out of that, maybe more.
I've only vacformed ABS (haircell), but I think it would work.
If anyone is familiar with this stuff, speak up.
I'm using Professional Plastics website (great company, very helpful and I highly recommend them). There are several options with the material. I decided that the General Purpose - Glazing Grade was fine for this application. You could go with the 1 inch thick bullet resistant stuff, but that's about 3 grand a sheet.
Thicknesses - .031, .062, .093, .125, .187, and up. I think either the .031 or .062 would be fine for this application. I have some .093 HIPS and it's pretty thick to use as a visor. Also, thicker means more expensive.
Type - Film masked or Paper masked. Paper masked may offer more durability during shipping, but it costs a little more per sheet.
Sheet size - anywhere from 12x12 (inches) up to 48x96 (4ft x 8ft). They will also cut your sheets to size. Very beneficial for shipping.
So thoughts on this?
According to this, the properties of forming polycarbonate sheets (lexan) is not too different than ABS. I think it cools quicker, but that shouldn't pose much of a problem.
My thought is this - create a mold for the visor, possibly even the double visor, and form the polycarbonate over it. That way you get a more 'bubble' visor than using motorcycle visors. Downside is that as far as I can tell it only comes in clear. But the price is really good - a 4ft by 4ft sheet is only $25, and I think you could probably get about 4 visors out of that, maybe more.
I've only vacformed ABS (haircell), but I think it would work.
If anyone is familiar with this stuff, speak up.
I'm using Professional Plastics website (great company, very helpful and I highly recommend them). There are several options with the material. I decided that the General Purpose - Glazing Grade was fine for this application. You could go with the 1 inch thick bullet resistant stuff, but that's about 3 grand a sheet.
Thicknesses - .031, .062, .093, .125, .187, and up. I think either the .031 or .062 would be fine for this application. I have some .093 HIPS and it's pretty thick to use as a visor. Also, thicker means more expensive.
Type - Film masked or Paper masked. Paper masked may offer more durability during shipping, but it costs a little more per sheet.
Sheet size - anywhere from 12x12 (inches) up to 48x96 (4ft x 8ft). They will also cut your sheets to size. Very beneficial for shipping.
So thoughts on this?