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WONDERFLEX is an extruded thermoplastic composite sheet. It is comprised of a proprietary synthetic polymer that when heated in the range of 150-170 degrees Farenhight (70-80 degrees C), will soften and activate its own adhesive for molding and forming. A layer of polyester open weave scrim is located on one side for added strength, reinforcement and stability, while the other side is smooth to receive paints and coatings.
WONDERFLEX is desirable for long lasting and durable items and oftentimes the material of choice over fiberglass, sculptured Styrofoam, paper mache etc. WONDERFLEX can be used in conjunction with craft/EVA foam or other materials such as FOSSHAPE.
Thickness is about .039 inches (1 mm) or a little less than 1/16 of an inch. Each full-size sheet only weighs about 3 ½ LB’s (1.59 Kilos). WONDERFLEX is tough and versatile, so in addition to heat activation properties, you can also drill, screw, bolt, staple or sew it.
Wonderflex is available in only one weight and thickness. WONDERFLEX can be built up using heat and pressure to bond several layers together, for additional structural support, stiffness or rigidity.
Wonderflex and Fosshape are both thermoplastics that use heat to activate them, but they are very different materials. WONDERFLEX is a firm thermoplastic sheet which becomes pliable with heat (heat gun, hot water, steamer) it has it’s own adhesive and will adhere to almost anything, once cooled it resumes its rigid state. Wonderflex can be reactivated and reformed. FOSSHAPE is a thermoformable non-woven-felt whose fibers compress and stiffen under heat and pressure, it will adhere to itself but for a more secure join stitching by hand or machine is recommended, once activated Fosshape can not be reshaped.
Sometimes either material may be suitable for your build and personal preference or skill set may prevail. Think about your project and what you are trying to achieve. What are the critical parameters involved? For a stronger, more sturdy build, then you might choose Wonderflex. If being light weight and or breathable are factors, you might choose Fosshape. The two materials compliment themselves well, so you might incorporate them both for the same creation and get the best of both worlds.
Wonderflex has been used in many applications, such as theatrical scenery and set designs, props, animatronics, puppetry, costumes, crowns, helmets, headdresses, armor, masks, mascots, wearable art, modeling, displays, taxidermy, custom interior auto repair, furniture restoration and as a quick repair patching item similar to duct tape.
It’s use is truly only “limited by your imagination”!
Artists, sculptors, prop masters, set designers, cosplayers, costume makers, mask makers, make-up artists, special effects artists and the like, have all discovered the wonders of WONDERFLEX. From high school and college theaters to Broadway, Hollywood and television, the use of new applications continues to grow. Successfully used in major theme parks worldwide, Opera houses, Halloween and haunted house attractions, Las Vegas venues, trade shows and special events.
The minimum purchase is just one full size sheet. Buy just one sheet or stock up and keep more on the shelf and ready for future projects. Purchased amounts of 1-15 sheets are rolled into a bundle and shipped in one box via UPS. We will email you with the UPS tracking information at time of shipment. Larger orders of 50 sheets or more can be shipped flat on a wooden pallet. Phone or email us if specific shipping requirements are needed.
The end result with WONDERFLEX is very similar to the end result of “Celastic”, but WONDERFLEX is much safer, faster and easier to use, with no special personal protection equipment required. Heat is all that is needed to activate WONDERFLEX, where as true “Celastic” required Acetone and personal protective gear such as respirators and solvent proof gloves.
WONDERFLEX can easily be cut with craft scissors or a utility knife.
A wide variety of heat sources maybe used, depending on the size of your project build. A pan of hot water, a steamer, or hot air gun are the most common ways to activate WONDERFLEX. Most users prefer working with an industrial hot air gun and or fabric steamers. Home hairdryers do not generate enough heat, 150-170 degrees Farenhight (70-80 degrees C), to provide an adequate activation temperature, especially if working on large pieces.
Working time is variable depending on the ambient temperature but advertises about 2-3 minutes of work or open time before it cools off and reverts back to its original stiffness. If you find it is becoming difficult to mold and shape as it cools off, apply more heat. WONDERFLEX can be heated again and again. If you need a shorter work time dip the piece in ice water to solidify the piece.
When heated, the WONDERFLEX activates the built-in adhesive, the adhesive does not readily transfer on to your fingers, unless you get the WONDERFLEX too hot. Some artists do work with their bare hands for the best dexterity…. you must be careful not to burn yourself, and it is recommended that you wear tightly fit, insulated gloves, especially when working on larger structures or for longer time periods. Since there is an inherent adhesive ALWAYS, use a release agent on your model or mold. We prefer aluminum foil to protect your matrix from the adhesive. The WONDERFLEX will adhere to the foil which can be removed once the piece is cooled.
Yes, it is well suited for both, positive and negative molds as well as free forming. Use conventional molds or create your own shape to form on. Wonderflex has its built in adhesive so you will want to utilize a layer of aluminum foil or spray on a non-stick release agent treatment like “Pam” non-stick cooking spray etc. Depending on the mold configuration or size, you may want to cut the WONDERFLEX into smaller pattern pieces or strips eliminating seams using heat and applied pressure.
Yes, cool or tepid water has no effect, so it’s OK if it “rains on your parade”. You can even use WONDERFLEX to build objects to hold water using adequate seaming/overlapping methods.
WONDERFLEX will stretch on the bias, due to the reinforcing polyester scrim support. Use the stretch factor of the heated WONDERFLEX to your advantage to enable you to work over curves or for finer detail. With a little work after heating, you can also peel off that fabric scrim layer, resulting in a mold-able “friendly plastic” for making small detailed parts.
With a little time, patience and experience the use of WONDERFLEX is truly “limited by your imagination”. Use traditional sculpting tools, a wooden tongue depressor, flat head screw driver, old spoons or whatever you have on had, to work more intricate areas. Once the fabric scrim is removed you can work with WONDERFLEX scraps or pieces like “friendly plastic”. An ice bag, gel cold pack or bowl of ice water, may help in speeding up the setup time or keep a newly formed area in tact while working an adjacent area with your hot air gun. Use the tip of a soldering iron or hot glue gun as your heat source tool without the glue stick for working on a small confined area and for seams. A wall paper seam roller works well on smoothing out seams.
Although some discretion is advised and every creation is case specific with respect to permanent placement, WONDERFLEX has been successfully used in outdoor theme parks etc.. In many applications, use of proper coatings and paints will adequately help insulate and protect the WONDERFLEX® from the sun.
Absolutely NOT! Activated WONDERFLEX and heat source can burn you.
No, it will eventually burn if exposed to an open flame long enough in its raw form or untreated state. Various flame-retardants available on the market can be used to cover or coat WONDERFLEX. Check your local fire regulations and confer with your local fire marshal regarding local regulations and your specific application or requirement.
WONDERFLEX readily accepts most paints and coatings. Acrylics, latex, spray paints etc. Foam coats, Sculpt-or-Coat, gessos, Crystal Gel or most any coating can be applied depending on the desired effect. Cover with decorative fabrics, leather etc. by applying spray adhesive or using the inherent adhesive in the WONDERFLEX.
WONDERFLEX is a thermoplastic, it will soften when exposed again to the 150-170-degree Fahrenheit temperature range, so use prudence in your selected storage location. Finished items should not be stored in outdoor metal storage trailers in direct sunlight or in your car in summer months where activation temperatures maybe reached.
Wonderflex World is in New Hampshire we do not charge sales tax so you do not need to supply a tax exempt number to order.
If an order is placed by noon EST it is generally shipped that same day.
We do workshops and sponsorships, but this is done on a case by case basis. We get numerous requests, so it is best to contact us with complete details.
Contact the founder of WONDERFLEX Brian Jeffrey directly at 603-778-0190 or email info@wonderflexworld.com Check out www.wonderflexworld.com for more information.