I haven't "stepped up" my system yet.
I've only made sheaths for myself, not for sale. Yet.
So far I've been happy with the results.
I started with minimal equipment.
* hand held heat gun.
* Two square foam pieces (I got mine from packing scrap, Not Styrofoam)
* .250" drill bit, and Drill.
* Strong shear or something to cut plastic.
* Sanding block/files
I bought a die set for setting rivets, but first started out using just Chicago screws. Then you don't have to worry about riviting.
I still don't have an arbor press, I set rivets with a hammer.
Best advice I can give, so far....
Just Do It.
It's easy!
-Tape blades for safety, and it helps with sizing the thermo mold.
- Use thinner sheets (.060" or less) it forms easier, more accurate.
- I use beer/pop can (cardboard) cases to practice my designs.
Hardest part is figuring out how You want to wear/carry your knife?
What works for you, what's comfortable?
Making the sheath is the easy part.
Buy more kydex than you need. You will find more sheaths to make.