pic: Lexan + Heatgun =
 

Re: pic: Lexan + Heatgun =
 

That is really cool. We will be making something almost exactly like that tomorrow. I've used a torch before to bend it, one of our mentors says to use a hot metal bar. What kind of a heatgun did you use? Did it discolor or bubble at all?

Re: pic: Lexan + Heatgun =
 

I've done a similar thing to the edges of my model train layout to protect the rolling stock in case of a derailment so it doesn't end up on the floor. I used 1/4" Lexan and heated it with a heat gun to match the contour of the edge of the layout. I have a variable temp (200-1200 degree) Milwaukee heat gun. I started at a lower heat and held it about 6" from the piece and slowly tried to bent it. I'm guessing I bent it around 350 degrees with the heat gun several inches from the Lexan. The amount you hold the heat gun over the piece will depend on the thickness of the material, the temp you're got it set at, and how far away you are from the piece. It's best to try it on a scrap piece first. Just remember some plastics are combustable.

Re: pic: Lexan + Heatgun =
 

We have a "machine" that has a strip like one in an oven the heats the lexan. We just lay it flat on it for about 15 sec, then bend and tah dah!

Re: pic: Lexan + Heatgun =
 

We used a 1300w heatgun. The board got a little tweaked from some areas getting hotter than others, but you cant tell it with out feeling the board. As for discoloring and bubbling, nah. The Lexan was 1/8" thick .. and took about 10 min to heat up the 34" strip of it. We had it clamped to the table with a 1x1 aluminum tube and some clamps on each side, and then one kid had a large 2x4 to bend the lexan.

Keep in mind, that lexan is flammable after 800 degrees (at least thats what the warning said on the plastic cover) So dont get it too hot .. and practice a few times on a spare piece, because it is a little tricky, and if you've never done it, you might wreck the expensive lexan.

Good luck.

(Edit)

Heres a picture of the setup we used to bend it ..

http://www.eaglerobotics.com/images/...an_bending.JPG