Cast vs. Extruded Acrylic

Property Cast Acrylic Extruded Acrylic
Laser Engraving Frosted, clean detail Poor or unclear
Edge Finish Slightly frosted Clear/glossy
Melting Point Higher Lower
Thickness Tolerance Slight variations More consistent
Price Higher Lower
Manufacturing Cell-cast in molds Continuous extrusion
Stress Levels Lower internal stress Higher internal stress
Cracking Risk Less prone to stress cracks More prone to cracking

Laser Settings Comparison

Material Type Thickness Cut Speed Cut Power Engrave Speed Engrave Power
Cast Clear 1/8” (3mm) 15-25 mm/s 80-100% 800-1200 mm/min 20-30%
Cast Clear 1/4” (6mm) 8-15 mm/s 90-100% 600-1000 mm/min 25-35%
Cast Clear 1/2” (12mm) 3-8 mm/s 100% 400-800 mm/min 30-40%
Extruded Clear 1/8” (3mm) 20-30 mm/s 70-90% 1000-1500 mm/min 15-25%
Cast Coloured 1/8” (3mm) 12-20 mm/s 85-100% 700-1000 mm/min 25-35%
Fluorescent 1/8” (3mm) 10-18 mm/s 90-100% 600-900 mm/min 30-40%

Note: Settings vary by laser power and brand. Always test on scraps first.

Acrylic Finish Options

Finish Description Best Use Laser Compatibility
Clear Transparent, glossy Signs, panels Excellent
Matte/Frosted Diffuses light, soft look LED edge lights, signage Very Good
Glitter Sparkling embedded effect Jewelry, tags Good (may chip)
Mirror Reflective surface Decor, name signs Fair (coating may burn)
Fluorescent Glows on edges Accents, keychains Good
Opaque Solid colour, no light pass Tags, layered art Excellent
Textured Surface patterns Decorative panels Variable
Two-tone Colour gradient Artistic projects Good

Thickness Guide and Applications

Thickness Metric Best Applications Cutting Difficulty Engraving Depth
1/16” 1.5mm Thin overlays, templates Easy Shallow
1/8” 3mm Signs, jewelry, small parts Easy Medium
3/16” 4.5mm Medium signs, boxes Moderate Medium
1/4” 6mm Sturdy signs, displays Moderate Deep
3/8” 9mm Thick displays, stands Difficult Very Deep
1/2” 12mm Heavy-duty applications Very Difficult Maximum
3/4” 18mm+ Structural elements Expert Only Multiple Passes

Quality Indicators

Quality Factor High Quality Poor Quality How to Check
Surface Finish Smooth, clear Scratched, cloudy Visual inspection
Edge Quality Straight, clean Wavy, rough Run finger along edge
Optical Clarity Crystal clear Hazy, distorted Look through material
Thickness Consistency ±0.1mm variation ±0.5mm+ variation Measure multiple points
Masking Film Easy removal, no residue Difficult, leaves residue Peel test corner
Internal Stress No stress marks Visible stress patterns Check under polarized light

Common Brands and Characteristics

Brand Type Quality Level Price Range Notes
Plexiglas Cast Premium High Industry standard
Lucite Cast Premium High Excellent clarity
Acrylite Cast High Medium-High Good laser performance
Optix Extruded Medium Medium Budget-friendly
Plaskolite Mixed Variable Low-Medium Check specifications
Generic Usually Extruded Variable Low Test before bulk purchase

Troubleshooting Common Issues

Problem Likely Cause Solution
Rough cut edges Speed too fast, power too low Reduce speed, increase power
Melted/rounded edges Power too high, speed too slow Reduce power, increase speed
Cracking during cut Material stress, wrong settings Use cast acrylic, adjust settings
Poor engraving contrast Wrong material type Use cast acrylic for engraving
Chipping on cuts Dull masking, wrong direction Fresh masking, check cut direction
Uneven engraving depth Warped material, uneven bed Check material flatness
Burn marks Power too high Reduce power, increase passes
Incomplete cuts Power too low, speed too fast Increase power or reduce speed

Buying Tips

Consider Why It Matters What to Look For
Masking Film Protects surface during cut Easy removal, no residue
Thickness Accuracy Important for layered designs ±0.1mm tolerance or better
Brand Quality Cast acrylic from known brands cuts cleaner Established manufacturers
Sheet Size Plan for bed size of your laser machine Standard sizes: 12”x12”, 24”x18”
Edge Condition Damaged edges affect cutting Straight, undamaged edges
Storage Condition Heat/UV exposure degrades material Cool, dry storage
Quantity Discounts Bulk purchases reduce cost Compare per-square-foot pricing
Return Policy Important for testing compatibility Supplier accepts returns

Safety Considerations

Safety Aspect Recommendation Why Important
Ventilation Always use exhaust fan Acrylic produces toxic fumes
Eye Protection Wear laser safety glasses Prevent eye damage
Fire Safety Keep fire extinguisher nearby Acrylic is flammable
Ventilation Testing Check air flow regularly Ensure proper fume extraction
Material Inspection Check for unknown coatings Some coatings release toxic gases
Emergency Stop Know location of emergency stop Quick shutdown if needed

Cost Analysis

Factor Cast Acrylic Extruded Acrylic Impact
Material Cost $3-8 per sq ft $1-4 per sq ft 2-3x difference
Waste Factor Lower (cleaner cuts) Higher (more test cuts) 10-20% difference
Time Efficiency Faster setup More trial and error 15-30% time difference
End Quality Professional results Variable results Affects selling price
Repeat Reliability Consistent results Variable batch to batch Customer satisfaction

Specialty Acrylic Types

Type Description Best Use Laser Performance
UV Filtering Blocks UV rays Outdoor applications Good, but slower cutting
Anti-Static Reduces static buildup Electronics enclosures Standard performance
Impact Modified Higher impact resistance High-stress applications May have different melting point
Coloured Core Different colour inside Layered engraving effects Excellent for two-tone engraving
Light Diffusing Scatters light evenly LED panels, lighting Good, creates soft glow
Non-Glare Reduces reflections Display cases, frames Standard performance

Project Planning Guide

Project Type Recommended Material Thickness Finish
Signage (Indoor) Cast Clear/Coloured 1/8” - 1/4” Clear or Opaque
Signage (Outdoor) Cast UV-Filtered 1/4” - 3/8” UV Resistant
Jewelry/Small Items Cast Clear 1/16” - 1/8” Clear or Coloured
LED Edge Lighting Cast Frosted 1/8” - 1/4” Matte/Frosted
Display Stands Cast Clear 1/4” - 1/2” Clear
Protective Panels Cast or Extruded 1/8” - 1/4” Clear
Decorative Items Cast Coloured 1/8” - 1/4” Various
Templates/Stencils Extruded (acceptable) 1/16” - 1/8” Clear

Updated: