thin sheet materials

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   I am trying to make a large cone shape (80cm diamter) out of laminated sheet. Its only a 20deg cone so not that much of a curve but I am having trouble. I have tried 3mm plywood but it is a little too stiff and the grain makes it bend a lot more easily in one direction than the other which makes it hard to make a symmetrical cone. There doesn't seem to be much hardboard/mdf thinner than 3mm. Does anyone know a source? Also considering using plastic sheet but I'm unsure of which type - can't be too brittle - and not sure what to bond the laminates together with. Any ideas?

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snowflake Members Profile Send Private Message Find Members Posts Add to Buddy List Old Croc Joined: 29 December 2004 Location: Bristol Status: Offline Points: 3122	Post Options Post Reply Quote snowflake Report Post Thanks(0) Quote Reply Topic: thin sheet materials Posted: 20 August 2021 at 12:44pm
	I am trying to make a large cone shape (80cm diamter) out of laminated sheet. Its only a 20deg cone so not that much of a curve but I am having trouble. I have tried 3mm plywood but it is a little too stiff and the grain makes it bend a lot more easily in one direction than the other which makes it hard to make a symmetrical cone. There doesn't seem to be much hardboard/mdf thinner than 3mm. Does anyone know a source? Also considering using plastic sheet but I'm unsure of which type - can't be too brittle - and not sure what to bond the laminates together with. Any ideas?

Jo bg Members Profile Send Private Message Find Members Posts Add to Buddy List Young Croc Joined: 08 March 2017 Status: Offline Points: 552	Post Options Post Reply Quote Jo bg Report Post Thanks(0) Quote Reply Posted: 20 August 2021 at 1:01pm
	Look for fromager ply - but before you could try to make the one you have wet and see if it bends easier. Or buy single sheets and do the plywood yourself layer by layer. This comes from previous research never did it myself, but could be food for thoughts.

woody2 Members Profile Send Private Message Find Members Posts Add to Buddy List Old Croc Joined: 04 March 2010 Status: Offline Points: 1726	Post Options Post Reply Quote woody2 Report Post Thanks(1) Quote Reply Posted: 20 August 2021 at 7:03pm
	Try "aircraft ply" - we get 8x4 1.2mm at our local yard then laminated if you need more strength.

markie Members Profile Send Private Message Find Members Posts Add to Buddy List Old Croc Joined: 31 October 2005 Location: Sunny Liskeard. Status: Offline Points: 4570	Post Options Post Reply Quote markie Report Post Thanks(1) Quote Reply Posted: 21 August 2021 at 2:44am
	Check out "Kydex". It's a thermoplastic sheet which softens when heated so can be shaped, then hardens as it cools. Available in several thickness' 1mm, 1.2mm 1.5mm, 2mm, 3mm. Not cheap, but then if it will do the job. Various colours/patterns. You can get a 3mm A4 sheet off ebay for under a tenner to play with and see if it will work out. Just tried some 1mm sheet and that softens nicely in boiling water. Edited by markie - 21 August 2021 at 3:07am
	If it's got wheels or tits it's gonna cost a fortune

snowflake Members Profile Send Private Message Find Members Posts Add to Buddy List Old Croc Joined: 29 December 2004 Location: Bristol Status: Offline Points: 3122	Post Options Post Reply Quote snowflake Report Post Thanks(0) Quote Reply Posted: 21 August 2021 at 11:37am
	thanks for suggestions. Just occurred to me that A0 paper size is over 800mm. Not easy to get non-corrugated card in A0 but will try phoning round some local printers. If I can get 0.5mm or 1mm can just build the layers up till stiff enough.