Wonderflex
From CosplayWiki
Wonderflex is type of thermoformable plastic encased in a polyester gauze or scrim. There are many other brand-names for this type of product, but Wonderflex is the most well known.
Advantages of Wonderflex
One major reason to love Wonderflex is that it's non-toxic. Previously used products such as Celastic or FORM-FAST required the use of toxic chemicals. There are no chemicals required to form and shape Wonderflex.
Wonderflex is easy to work with. Heat a sheet up to 150 degrees Fahrenheit and Wonderflex becomes soft and pliable like a thick sheet of cloth. Wonderflex will be malleable as long as it remains heated. One of the safest and easiest ways to heat Wonderflex is by using a Heat Gun. Heat Guns are just absurdly powerful hairdryers. Wear protective gloves when applying heat to Wonderflex.
Wonderflex is capable of holding mulitple, complex curves, the reason being Wonderflex is capable of stretching under the right circumstances.
Wonderflex binds to itself. It is possible to bind 2 pieces of Wonderflex to each other by applying heat.
If you are not happy with the shape you’ve created, reheat the Wonderflex and reshape it.
Disadvantages of Wonderflex
The most common complaint about Wonderflex is that it is not easy to obtain and it is very expensive. Most craft stores will not carry Wonderflex or similar materials. It can be purchased off the internet and prices usually range from about US$25-US$30 for one square yard.
The second biggest issue with Wonderflex is finishing it. Most primers can be peeled away and may flake off over time. Reapplying primer and paint may not always be an option. Making Wonderflex smooth has been a source of consternation to many people as well. Known methods for smoothing Wonderflex include applying and sanding layers of Gesso or Bondo, melting Friendly Plastic over it, varnishing it and wrapping it with fabric.
When working with wonderflex something to take into consideration is that it will NOT automatically form many complex curves that people are looking for. You will need to press it around something solid or into something to get it into the shape you are looking for.
