Mica and many of the metals, solvents, and materials we use can be toxic. Any experience I share here must be used at your own risk.
How To Cut & Bend Mica
I cut mica with a band saw or scroll saw with a fine tooth blade, or metal shear. When doing this the saw generates a silica dust that is toxic and known to cause silicosis.
I bend mica with heat, approximately 500 degrees. I have used everything from a common blow dryer or painter's heat gun, to a special oven that I only heat mica in. I have heard that some people use the microwave. I preheat my oven to 500, insert the mica, and count out seven seconds. If this does not do the trick, I reinsert the mica and give it another shot of heat, it can help to flip it and heat botrh sides. When the mica cools, it will hold its shape.
WHAT IS MICA SHEET?
Mica sheet is composed of thin mineral mica crystals that are laminated or held together with shellac or vinyl resin. Unpurified shellac has a natural yellow cast that gives the amber mica its color. Vinyl resin is clear and allows the mica to show its natural mineral color. Most clear raw mica flake being used now has a slight red cast called ruby that can be seen when a sheet is laid on a white sheet of paper. Other mica may have a greenish tint from the influence of copper on the mineral.