What is the best way to cut 3mm sintra?

[Mandalorian2112]

I recently acquired a large sheet of 3mm thick sintra to use on an ESB Boba Fett Costume but I had a bit of trouble attempting to cut it. This is my first time using sintra and I would appreciate any suggestions on how to cut it.

 

[Mullreel]

For thin sintra I have usually just used a utility knife. Score it then cut deeper and so on, it doesn't take that much effort and the razor quality of the utility knife cuts a nice edge.

 

[Mandalorian2112]

Thanks for the help! I also wondered if anyone had any tips on how to heat larger pieces of sintra to form it?

 

[PunisherFett]

A large pot of hot water.

 

[Mullreel]

I use a heat gun, like the kind you find in the paint section.

 

[Mandalorian2112]

Thanks. What precautions should I take about fumes from the heated plastic?

 

[Mullreel]

It shouldn't be that bad but open a window, turn on the ceiling fan. That should be enough. 3mm Sintra is fairly thin and it won't take that much to heat it up. It shouldn't be putting off much fumes.

 

[Mandalorian2112]

Thanks again. Sorry for al the stupid questions but I've got another one. For the inside frame to shape the helmet around (I'm using Wizard of Flight's templates), what material should I use? I've heard that making the frame out of cardboard and putting the sintra around works good but I figured I'd double check.