Q&A for How to Easily Mold Acrylic Plastic Sheets

It depends on the thickness of the acrylic and the key is to warm it up slowly. If you do it in any cold environment, it is more likely to crack. It's a matter of trial and error and being patient with it. Start with a blow dryer at a medium setting to soften it and then once it gets soft enough to where it's pliable, gently bend it.

In most cases yes, but if you're using a kind of plastic that either has a very low combustion temperature, or gives off nasty fumes when heated, then I would suggest using an air mask to protect yourself. Look online to see whether this sort of thing would happen with your specific type of plastic. This will not happen for acrylic sheets, as they are safe to mold.

Depending on what type of plastic it is, it probably will stick to it. You can put parchment paper sheets between the mold to avoid this, but the heat from the thermoplastic may warp the mold.

The aluminum got too hot and began to burn the plastic, or the oven was too hot. Either way, the bubbles can be sanded or flame polished.

Make a fixture with Heater Road and put a plain sheet on it. As it get hot, put it in a wooden mold(make a as your requirement), and press it on press. As the part temperature gets normal, open that wooden case and make some correction via the grind machine.