Transparent. Reasonably flexible - ie can accept some flex
I might have come up with a way of “mass” producing my glowing animal masks…
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vac-form?
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That’s really small. I’d imagine you’d have to shape a sheet and then cut them out.
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…or a strip
I can imagine a neat little machine that pushes a flat strip through heated wheels, and a rotating blade that slices off one piece at a time. Kinda like a pasta machine
https://i.imgur.com/ksPKsEt.gif
But that’s a metal-working project beyond my (and the space’s) ability.
The idea is to push each one of these through a rectangular slot in a folded sheet of polypropylene, then thread el-wire through the U, this holding it in place. I originally thought of using bent wire clips, but they’d present sharp/pointy edges on the inside, and point loads to the wire and sheet.
Not as fast and efficiant, but you could maybe make a jig and bend a sheet of something, then cut it into strips - 3 bends, then run a load off on a bansaw or similar. Possibly you could use a strip heater on acrylic, push into mould or bend on jig, then cut…?? If you actually mean 100s, then talk to someone about injection moulding 
I was thinking something like this would be effective. But how many?
Cable ties FTW!
Ugly, leaves sharp corners when trimmed, and relatively expensive in these numbers!
You probably already looked, but why not this? They’re bigger, but gets you pretty close. Thread through and do the final bend with pliers to lock in.
http://www.screwfix.com/p/prysmian-ap7-white-clips-pack-of-100/89697
http://www.safetechsuppliers.co.uk/media/blfa_files/0900766b81103cf8.pdf
Hmm, a bit overkill. And rather labour intensive?
I bet there’s a factory in China somewhere that’s already making little doodads like this by the thousand, destined for some obscure assembly process somewhere. Impossible to google.
Yeah. But apart from that…?
You could probably build a set of progressive rollers from Lego. We should get some Lego.
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Half the entire space under my bed is lego 
But you’ll need that on s few years time!
Damn right! That stuff’s going nowhere
Could turn up rollers on the wood lathe we’ve been promised
Meccano…?
Just to slap myself in the face a little, the amount of time I have to spend on this is vanishingly small. It will grow in the future though, so it’s worth thinking about.
The interest in those masks has always been very intense, but the answer to “can I buy one?” has always been “starts at £500 to make it worth my time” cos they’re so labour intensive.
If I can make the actual shape from folded/bent laser-cut polyprop sheet and a handful of pop rivets, and have a glueless, tool-less method of laying the wire on, then it might actually make sense to do a run for sale.
Here’s those clips in action:L
