I first carefully sketched out a shape with various curves and angles on the double block of MDF, and cut the perimeter out on the small band saw, using relief cuts for the one tight curve. Then I filed and sanded the edges smooth with 80 grit, and chose a simple rounded edge bit for the router. The router wasn't able to completely get into the one interior angle, so I filed it slightly by hand. Then it was ready to be vaccuformed, which went pretty smoothly I think.
The styrene was trimmed from the mold and released, and I will be sanding, assembling, and finishing it today.
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