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Thermo / Vacuforming blanks... Here's my master mold!

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I sculpted a canine "master mold" out of air dry clay last night.  This will serve as my test subject once I finish building my vacuum table later this week.  I *really* hope this works because I am tired of having to build suit heads from scratch with foam.

With this blank I hope to be able to make various types of canines, adding foam to the plastic bases to make them look more wolf-like / fox-like / etc. as needed.

Probably a dumb question, but in order to make a hinged jaw using a vacuformed blank, I assume you would assemble it similar to how you would a resin blank?

EDIT: I am looking for a good thermoplastic to use in a kitchen oven... I've read on several sources that most thermoplastics won't release toxins into the air as long as they aren't overheated.  Is this true? If so, what would you guys recommend?  And if using a kitchen oven is a bad idea, where would I find a decent craft bake oven?


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