How can I make a Plexiglass mold of my abdomen?

Question

Or really, out of Polycarbonate (AKA, Lexan... AKA Plexiglass on steroids). 

I'm trying to figure out how to make an accurate mold of my abdomen (possibly limbs in the future), with a sheet of thin Lexan. The obvious problem is that sheet Lexan it cannot be molded without heat, and that when it is that hot, it cannot be pressed against the body.

I've tried to think of ways to come up with a print of my abdomen to press the Lexan against.... Clay (too slow to dry), MODELING clay (too expensive for such a large amount), ballistics gel (Must be "frozen" in a fridge for hours on end), plaster (I have no idea how it works, where to get it, or if it can withstand the heat of molten Lexan). I'm running out of things to Google.

It's an experiment in body armor if you're wondering.

? · Accepted Answer

The first answer leaves out a couple of steps and a warning that should be there.
The most basic answer is that you can mold heated Plexiglas (acrylic sheet) or Lexan (polycarbonate) against plaster without problems as long as the force and be applied quickly.  
 You really don't need to make a latex mold of your abdomen for what you want to do - it holds much more detail, but you don't need detail  You do need to take care that you don't make the plaster too thick on your body - it gives off heat in setting - higher temp with thicker pieces - so you cast a thin layer backed with plaster soaked gauze and when that is set, you apply more plaster and cloth to the back to strengthen it.
 Based on my experience with acrylic (and I have not done polycarbonate) you will have to do one of two things to get the right form - you will have to line your negative mold with a towel covered with plastic to make a somewhat smaller inside plug by layering plaster inside - you then trap the hot plastic between the plug and the mold and push in.   Or you get a lot of sand - preferably warmed and dry - and after you put the hot plastic in place and perhaps put a protective sheet of soft plastic film over the sheet you have pushed into place - you quickly pour the hot sand to apply weight.  
 Fortunately, if the molding process fails, you can reheat the plastic to flatten it and try again.
 And, by the way, you can wet leather and mold it to shape - it gets harder than it was in the first place when it dries.

MOZ · Answer

You get plaster at any hardware store like Home Depot or Lowes, and some WalMarts carry it in the paint dept.
You will also need some latex mold casting rubber.  (see sources) You may find it at Craft stores OR also at hardware stores, never hurts to ask.

It will be a 3 step process.

1. cover your abdomen with the latex mold rubber.
2. When cured, fill the mold with plaster of paris and let it cure 
3. Once cured, it will be a plaster model of your abdomen. You can then put the Lexan over it and heat it to mold against the plaster. When it cools, take it off. 
Voila! Form fitting Lexan sheet.

Anonymous · Answer

plaster is good for a general reproduced image, for more detail usa a moulage, is is a heat able rubber ,use it as a 1st layer ,back up with plaster, the when that has cured, mix plastic resin and pour the in your mold for a clear cast or for more strength back that up with fiber glass fiber

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How can I make a Plexiglass mold of my abdomen?

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