When I started working on Precious Plastic we were using a tiny T-Shirt press to make the rough-edged sheets seen on the first page. One of my earliest projects was figuring out how to refine the sheets into badges. I found that I could make molds out of metal and as long as they got up to temperature they worked perfectly for making sheets of consistent size.
I used this knowledge to make several different sizes of molds and sheets of plastic. I made a run of 40 badges for a conference at the Ion downtown. I also aquired two t-shirt presses and combined them into a super press capible of turning out a 1 ft by 2 ft sheet in about an hour.