Abstract: A forming mold and method using the forming mold to form thermoplastic sheets into a more comfortable and concealable weapon holster. The two piece forming mold includes an upper section and a lower section having mating concave and convex surfaces. The upper section includes a deformable foam pad mounted to its concave inner surface and the lower section includes a deformable foam pad mounted atop its convex upper surface. The curvature of the mating concave and convex surfaces approximates the curvature of the average human hip. The foam pad mounted to the concave inner surface of the upper mold section is thicker than the foam pad mounted to the convex outer surface of the lower mold section.