Heres a few photos of my home made plastic vacuum former and its maiden test. If you don`t know what vacuum forming is check here, and youtube.
Essentially a sheet of heated plastic is placed over some kind of mould which then has the air sucked out from underneath it. The soft plastic schloops to the shape of the mould and when it cools you have yourself a robot part. It really does sound like schloop if you`re wondering.