[awerby]

I'm not sure why you need a 5 axis machine to make forms for vacuum-forming - don't they need to be able to release? But in answer to your question; for this sort of thing look into the high-density urethane tooling board materials, like Precisionboard and Butterboard. They carve easily, hold good detail, and should last a while.

[ChristianLL]

Awerby, thanks for the advise on the tooling board, I've had urethane in mind, but it seems to be hard to find that kind of stuff my area.

The reason I want a 5 axis machine is because the body shells will have undercuts on two sides e.g. left and right sides of the car. Then I can cut two slits at the front and back to flex the formed plastic outwards and easily lift it off. That's the plan, anyway.

[1Jumper10]

Hey man, you've really got a nice build going there! You're very talented. My hat is off to you sir! :cheers: