Plaskolite Acrylic Sheet Fabrication Guide

24 Pages·2009·2.09 MB·English

CONTENTS
PAGE
 INTRODUCTION 2
PHYSICAL PROPERTIES 2
OPTIX FEATURES 3
DURAPLEX FEATURES 3
OPTIX PHYSICAL PROPERTIES TABLE 4
DURAPLEX PHYSICAL PROPERTIES TABLE 5
FABRICATING 6
ACRYLIC SHEET CARE 6
CUTTING 6
®
MACHINING 7
CUTTING & MACHINING TIPS 8
ANNEALING 8
FINISHING OPERATIONS 8
CEMENTING & FASTENING 9
DECORATING & PAINTING 10
FORMING METHODS 11
PLASKOLITE
OUTDOOR SIGNAGE 13
MATERIAL
ROLL STOCK SPOOL DIMENSIONS 13
TRANSPORTING ROLL STOCK 13
EXCELLENCE
DETERMINING SHEET THICKNESS 14
DETERMININING SHEET SIZE 14
SIGN ASSEMBLY 14
TROUBLE SHOOTING GUIDES 16
ISO 9002 Registered
CHEMICAL RESISTANCE 18
SUGGESTED VENDORS 19
PLASKOLITE, INC.
P.O. Box 1497 Columbus, OH 43216
614/294-3281 800/848-9124
Fax: [phone]
Email: [email protected]
www.plaskolite.com
1
PLASKOLITE FABRICATION GUIDE
INTRODUCTION PLASKOLITE acrylic sheet is an excellent choice for a
variety of industries, including: signage, store fixture,
P.O.P. display, skylight, building/window, hobby/
PLASKOLITE is a leading manufacturer of acrylic
craft, lighting, and the automotive aftermarket.
sheet, acrylic resin, polystyrene sheet and acrylic
mirror sheet products. Since 1950, it has built an
excellent reputation for providing superior quality
products and responsive customer service.
PLASKOLITE’s commitment to quality extends
over every aspect of its business. From our 350,000
sq. ft. manufacturing and distribution headquarters
in Columbus Ohio, 240,000 sq. ft. facility in Zanes-
ville, Ohio, and an 80,000 sq. ft. facility in Comp-
ton, California, PLASKOLITE delivers flawless quality
sheet and resin to customers worldwide.
To better serve customers, sheet can be ordered
in customized “Run-to-Size” dimensions, special pat-
terns, and thicknesses. Inside sales representatives
use automated order and shipping tracking systems
to provide customers with up-to-the-minute order
information.
From manufacturing, through customized prod-
uct offerings, packing, shipping and order tracking,
PLASKOLITE is committed to delivering the highest
quality products and service.
PHYSICAL PROPERTIES
PLASKOLITE acrylic is a continuously processed
sheet made through a fully integrated manufacturing PLASKOLITE’s acrylic sheet meets the following:
process that converts acrylic monomer into acrylic
polymer, then into acrylic sheet. It is crystal clear, ISO 9000 Quality Registration received in 1994
glossy, durable, weather resistant, and lightweight. International Code Council Evaluation Service
Advantages of PLASKOLITE acrylic sheet include; (ICC-ES) listings as CC2 Plastics (incorporates
high molecular weight for ease of fabrication, low former ICBO, SBCCI, BOCA and NES certifica-
heat loss for economy, and an attractive clear edge tions)
color. ANSI Z97.1 Safety Glazing Requirements
PLASKOLITE produces OPTIX standard grade ANSI Z26.1 (AS-6) Motor Vehicle Safety Stan-
acrylic and DURAPLEX, which has an impact modi- dard
fier blended with the acrylic resin. Acrylic sheet is Underwrites Laboratories (UL) listings as UL
available with a smooth, nonglare or patterned sur- 94HB and UL746 Compliant
face, in clear, translucent, and transparent colors. Miami-Dade County Product Notice of
Supplied thicknesses range from .040” to 1.0”, and Acceptance-Plastics
widths up to 105”. 10-year limited warranty on all clear acrylic
The Run-to-Size program allows sheet to be sup- sheets
plied at specific size requirements. This flexibility ASTM D-4802 B-1 Plastics
saves you time, eliminates scrap, improves produc-
tivity and reduces wear and tear on your equipment.
2
OPTIX FEATURES
100
N
O
SI
SCRATCH RESISTANCE S
MI 80
S
OPTIX acrylic sheet is one of the most durable N
A
tahlseor mooffpelraesdti cw mitha teanri aalsb rfaosri orne srisetsinisgta snct ractocahteinsg. ,I to ins HT TR 60 GLASS SHEET
one or two sides, to protect from excessive scratch- LIG RD LIC
ing. OF 40 DA RY
E N AC
AG TA X
TEMPERATURE RESISTANCE NT 20 S PTI
E O
C
OPTIX acrylic sheet can be used continuously R
E
P
in a temperature range of 170-190°F. OPTIX acrylic
sheet begins to soften between 210-220°F and starts 300 340 380 420
to melt between 300-315°F. OPTIX acrylic sheet Figure 1 WAVE LENGTH OF LIGHT, NANOMETERS
can withstand temperatures down to -20°F without
DURAPLEX FEATURES
noticeable changes in properties.
LOW HEAT LOSS
In addition to the features of OPTIX acrylic sheet,
DURAPLEX acrylic sheet can offer the following:
Compared to a glass panel, OPTIX acrylic sheet
reduces heat transfer and solar heat gain through the
sheet. The R value is .86, which describes the degree IMPACT STRENGTH
of insulation provided by acrylic.
50% medium impact modified acrylic sheet is 10-
15 times stronger than double strength glass, and 20-
IMPACT RESISTANCE
30 times stronger than polished wire glass or other
glasses.
OPTIX acrylic sheet is between 2-10 times stron-
100% high impact modified acrylic sheet is 20-
ger than double strength glass. Half the weight of
30 times stronger than double strength glass, and
glass, and shatter resistant, acrylic sheet is easy to
40-50 times stronger than polished wire glass or
transport.
other glasses.
Custom blends are available to meet specific
EDGE COLOR
impact requirements.
OPTIX acrylic sheet offers crystal clear edge color,
and excellent optical properties. DURABILITY
DURAPLEX acrylic sheet is great for damage-
LIGHT TRANSMISSION
prone uses, and rough handling.
OPTIX acrylic sheet has a light transmission of
92% and a haze of 2% or less. WEATHERABILITY
DURAPLEX acrylic sheet is an economical alter-
WEATHER RESISTANCE
native to polycarbonate. It offers significantly more
OPTIX acrylic sheet is recommended for both weatherability than standard PETG or polycarbonate.
indoor and outdoor use. It is able to withstand pro-
longed exposure to the sun and the elements. FORMING BENEFITS
DURAPLEX offers a wide operating window of
ULTRA VIOLET FILTERING
forming temperatures (270-375°F). DURAPLEX is
OPTIX acrylic sheet filters out between 80-90% easy to form, with short heating cycles. Excellent
of the UV light within the damaging wavelength part definition, no required predrying, low orienta-
area of 250-400 nanometers (See Fig. 1). tion, and low shrinkage are all benefits of forming
PLASKOLITE acrylic sheet.
3
38304.1_32 4/30/04 4:15 PM Page 4 (Black plate)
ACRYLIC SHEET PROPERTIES
®
Optix® Acrylic Sheet Properties
ASTM Test Units Values Thermal ASTM Test Units Values
ASTM ASTM
Method Method
Physical Test Test
Properties Method Units Values Thermal Method Units Values
Maximum °F 170-190
D-792 1.19 recommended
Specific Gravity D-792 1.19 Maximum °F 170-190
continuous service
Recommended
D-542 1.49 temperature
Optical Refractive Index D-542 1.49 Continuous Service
Temperature
Softening temperature °F 210-220
Light Transmittance D-1003
D-1003
Total % 92 Softening Temperature °F 210-220
% 92 Melting temperature °F 300-315
Haze % 2
% 2
Melting Temperature °F 300-315
Deflection temperature D-648
E 90-70 db 27 load, unannealed
Sound Transmission E 90 db 27 Deflection Temperature D-648
E 413 3.6°F/minute, 264 psi °F 190
E 413 264 psi °F 203
3.6°F/minute, 66 psi °F 205
66 psi °F 207
%
Water Absorption D-5D70-570 By we%ight 0.4.040 Coefficient of thermal D-696 ins/in/°Fx
By Weight C eoxepfafincsieionnt of Thermal D-696 in/1(i0n--5°F)
% -E4x0p°aFnsion x10-5 2.7
Shrinkage D-7D02-702 Shrink%age <<55%% --2300° Fto 30°C 23..90
Shrinkage 0°F 3.1
Thermal Conductivity C-177 BTU-ft/ 0.075
20°F 3.2
(hr-ft2-°F)
40°F 3.4
MMeecchhaanniciaclal 6Fl0a°mFmability D-635 in/minute 13.0.619
8(B0u°Frning Rate) 3.9
Tensile Strength - Max. D-638 psi 11,030 100°F 4.3
TTeennssiliele s Etrleonnggthation - Max. D-638 psi% 105,1.800 Smoke Density Rating D-2843 % 3.4
T menasxiilme uMmodulus of Elasticity psi 490,000 Thermal conductivity C-177 BTU .9
Tensile elongation % 5.1 Self-Ignition D-1929 (HR)(F°t2F)(°F/in) 833
F mlexaxuirmalu Smtrength - Max. D-790 psi 17,000 FTleammmpearbailtiutyre D-635 ins/minute
MFleoxduurluasl Mof oedlaustluicsit yof Elasticity psipsi 443910,,000000 (burning rate) .060” Sheet 1.019
Flame Spread Index E-84 115
.236” Sheet .318
Flexural strength D-790 psi 14,600 Smoke density rating D-2843-77 %
I zmoadx iImmupmact Strength - D-256 ft-lb/in 0.4 Smoke Developed Index .236” .53560
Molded Notch Notch Self-ignition temperature D-1929 °F
Izod molded notch D-256-56 Ft lbs/inch .4 .236” 833
1Iz/o2d” xIm 2 p1a/2ct” Sxt 1re/4n”g tbha r- of nfot-tlcbh/in 0.28
aMt 7ill3e°d Notch Notch FClahmeem sipcraelad index/ E-84-86 .375” 110
Tensile Impact Strength D-1822 ft-lb/in2 20 Smoke developed index .236” 115
Izod milled notch Ft lbs/inch .28 Resistance to Stress - ARTC
1/2” x 2 1/2” x 1/4” bar of notch Critical Crazing Stress modification
Abrasion Resistance D-1044
at 73° to: of
Change in Haze
MIL-P-6997
T0e ncsyiclele ismpact strength D-1822 Ft Hlba/izne2, % 200 CIshoepmroicpayll Alcohol psi 900
10 cycles Haze, % 11.2
Lacquer Thinner psi 500
50 cycles Haze, % 24.0 Resistance to stress - ARTC
Abrasion resistance D-1044 Toluene psi 1,300
200 cycles Haze, % 24.9 Critical crazing stress modification
0 cycles Haze, % 2 Solvesso 100 psi 1,600
of
10 cycles Haze, % 15
Rockwell Hardness D-785 M-95 to: MIL-P-6997
50 cycles Haze, % 30
200 cycles Haze, % 50
Isopropyl alcohol psi 900
Lacquer thinner psi 500
ThReoscekw seulgl gHearsdtinoensss and data aDre-7 b8a5sed on information weM b-9e3lieve
Toluene psi 1,300
to(s abme prleel itahbiclekn. eTshse .y2 5a0r”e) offered in good faith, but without guar-
Solvesso 100 psi 1,600
antee, as conditions and methods of use are beyond our control.
We recommend that the prospective user determine the suit-
These suggestions and data are based on informa-
ability of our materials and suggestions before adopting them on
tai oconm wmeer cbiael lsiceavlee. to be reliable. They are offered in
good faith, but without guarantee, as conditions and
PLASKOLITE, INC.
methods of use are beyond our control. We rec-
P.O. Box 1497 • Columbus, Ohio 43216
ommend that the prospective user determine the
ISO 9001 Quality System 614/294-3281 • FAX: [phone]
suitability of our materials and suggestions before Email: [email protected]
adopting them on a commercial scale. www.plaskolite.com
Plaskolite, Inc. 2/04 1-800-848-9124
Printed in U.S.A. 4
4
38304.1_32 4/30/04 4:16 PM Page 11 (Black plate)
38304.1_32 4/30/04 4:16 PM Page 11 (Black plate)
C
IC
L
Impact Modified Acrylic Flat Sheet
I
® ACRYLIC SHEET PROPERTIES
YL
Impact ModifieIdm pAacctr yMloicd ifFielad tA Scrhyelice Stheet
RY
®
Impact Modified Acrylic Sheet
Physical ASTM Test Units  ® ® ® ®
CR PROPERTY Properties MethAodSTM UNITS SG 30% I30% I 505%0 I% I 7700%% I I 110000%% I I
SG05 SG10
®
Optical Optical
Light TransmittLaignhcte transmission D-1D00-31003 %% 92 92 92 92 9292 9900 9900
AC PRPOePrcEeRnTtY Haze Percent haze D-1D0A0-31S0TM03 %UN%ITS 2 2 2 302% I 2502% I 7<0<3%3 I 10<<033% I
MOpectihcaanlical Mechanical
Impact strength izod impact (73°F) D-256 Ft lbs/inch 0.4 0.6 0.7 0.9 1.11
IzoLdi gImhtp Tarcatn sSmtreitntagnthce DD--1205063 ft.lb%s./in. 09.24 09.26 09.27 09.09 19.01
Tensile modulus D-638 psi 430,000 376,000 340,000 304,000 250,000
A TenPseilrec eMnto Hdualzues of Elasticity DD--1603083 P%SI 4902,000 3762,000 3402,000 304<,3000 250<,3000
Tensile strength @ yield D-638 psi 10,500 9,000 8,000 7,100 5,600
Tensile Flexural streSntgrethn @g tyhie @ld YieldD-7D90-638 psiPSI 14,60101,03013,6909,000 12,800,0000 170,,611000 58,,630000
Mechanical
FlexuralRockwell hardneSstsr Menegthtohd @A YieldD-7D85-790 PSI 9617,000 7813,690 6182,000 1059,610 8,43600
D Izod Impact Strength D-256 ft.lbs./in. 0.4 0.6 0.7 0.9 1.1
Rockwell Hardness Method A D-785 95 78 68 59 46
Tensile Modulus of ElasticThiteyrmal D-638 PSI 490,000 376,000 340,000 304,000 250,000
ThTeenrsmilael DeflectionS ttermepnegrathtu r@e YieldD-64D8-638 °FPSI 20511,030 2009,000 1984,000 718,1800 51,68000
(Annealed) (264psi)
FlexuDraelflection TempSetrraetnugreth ( 2@6 4Ypieslid) DD--674980 P°SFI 172,00300 131,96890 121,90400 101,96010 81,38050
D Coefficient of linear D-696 in/in °F 3 x 10-5 3.5 x 10-5 4 x 10-5 4.5 x 10-5 5 x 10-5
E RockCwoeelfl fiHciaerndtn oetfsh seTrhmearlm exapl aEMnxsiepotnahnosdi(o0 A-n100°FDD A--v67g98.)65 in./(in.-°F) 3.0 9x5 10-5 3.5 7x8 10-5 4 x6 180-5 4.5 5x9 10-5 5 x4 160-5
Self Ignition Temperature D-1929 °F 833 >850 >850 >850 >850
Thermal
Self ignition temBpuerrantuinreg RateD-19D29-635 in°F./min. 8331.019 >8500.85 >8510.25 >185.503 >18.9507
Deflection TemperaBtuurrne r a(2te64psiD)-635D-8-8648 in/mi°nF <0.5 203 0.85 198 1.25194 1.15930 11.9875
I Smoke Density Rating D-2843 % 3.4 5.20 8.50 11.5 16.5
E Coefficient of Thermal Expansio(.1n77” SDh-e6et9)6 in./(in.-°F) 3.0 x 10-5 3.5 x 10-5 4 x 10-5 4.5 x 10-5 5 x 10-5
F SeSlfm Igoknei tdioenns iTtye rmatpinegratureD-28D4-31929 % °F 0.36 833 5.20 >850 8.5>0850 1>18.550 >186.550
(.177” Sheet)
Burning Rate D-635 in./min. 1.019 0.85 1.25 1.53 1.97
Processing
II Density SmokeS PDproeeccneissfiisctiy nG gRraatviintgy DD--2789423 % 13.1.49 15..1280 18..1570 11.11.65 11.61.55
Specific gravity D-792 1.19 1.18 1.17 1.16 1.15
F Moisture Water Absorption D-570 % wt. gain 0.4 0.3 0.3 0.3 0.3
D Water absorption D-570 % wt gain 0.3 0.3 0.3 0.3 0.3
ProDcimesesninsigonal MoMldoinldg isnhgrin SkahgreinkageD-9D55-955 mimls/iilnsc.h/in. 2-6 2 -6 3-6 3 -6 3-63 -6 33- 6-6 33 --66
I Density Specific Gravity D-792 1.19 1.18 1.17 1.16 1.15
Moisture Water Absorption D-570 % wt. gain 0.4 0.3 0.3 0.3 0.3
DURAPLEX / Polycarbonate Comparison
D
O Dimensional Molding Shrinkage D-955 mils./in. 2 -6 3 -6 3 -6 3 -6 3 -6
Feature Duraplex Polycarbonate
Weatherability Excellent weatherability Yellows and less glossy when exposed
O These values are nwoitht nino timepnadcte odr ofpotirc asl peciftioc sautniloignht., lessens impact strength
property reduction after exposure
M
Forming Better meDlt sutrernagtph lex/PLoowly mcelta strrebngothnate Comparison
These values are nNoo pt riendtryeinngd reeqdu irfeodr specifOicftaent iroeqnu.ires predrying
M Forming temperature Wide range (275°F-350°F) Distinct high forming temperature
Feature Duraplex Polycarbonate
Short cycle times Long cycle times, more energy cost
Duraplex/Polycarbonate Comparison

OWpteicaatl hclearritaybility Very clear Excellent weLaetshs eclreaabr, ihliatzyy, shows distortionYellows when exposed to sunlight,
T with no impact reduction lessens impact strength after exposure
Cost Feature Considerably less than poly-DuExrpaenpsilveex Polycarbonate
carbonate
Forming Better melt strength Low melt strength
Weatherability Excellent weatherability Yellows when exposed to sunlight,
C
T with no impact reduction lessens impact strength after exposure
Forming Temperature Wide range (275°F–375°F) Distinct forming temperature
Forming Better melt strength Low melt strength
Optical Clarity Very clear Less clear, hazy, shows distortion
AC
Forming Temperature Wide range (275°F–375°F) Distinct forming temperature
Cost 40% less than polycarbonate Expensive
Optical Clarity Very clear Less clear, hazy, shows distortion
A
P
ThCeosset suggestions and data ar4e0 b%a sleesds othna inn fpoormlycaatirobno nwaete believe Etox pbeen srievleiable. They are offered in good
faith, but without guarantee, as conditions and methods of use areP bLeyoAndS ouKr cOontrLol.I TWEe r,e coImNmCend. that
M the prospective user determine the suitability of our materials and suggestions before adopting them on a
P
commerRciaul snca-lteo. -Size Available P.O. Box 1497 • Columbus, Ohio 43216
614/294-3281 • FAX: [phone]
5 PLASKOLITE, INC.
M Email: [email protected]
Run-to-Size Available P.O. Box 1w4w9w7 .•p Claoslkuomlibteu.sc,o Omhio 43216
I Plaskolite, Inc. 2/04 6114-/28940-32081- •8 FA4X8: 87-79/51328-04754
Printed in U.S.A. 11
Email: [email protected]
www.plaskolite.com
I Plaskolite, Inc. 2/04 1-800-848-9124
Printed in U.S.A. 11
cutting tool, or Fletcher Terry Knife. Score to pen-
etrate 1/3 through the sheet. Align the score with
CARE
the edge of the table and apply gentle pressure to
break the sheet along the score line (See Fig. 2).
SAFETY CONCERNS
Acrylic sheet is a combustible thermoplastic, it will
ignite and burn if placed in open flame or in contact with
any other source of ignition. When storing or working
with acrylic sheet, please be aware of the thermoplastic
properties and consider fire precautions.
STORAGE
PLASKOLITE acrylic sheet is best stored horizon-
tally, on the supplied flat bulk skids, in a well ven- Figure 2
tilated, consistent temperature area. Avoid storing
CUTTING
acrylic sheet where extreme temperature variations
occur, and areas above 100°F. Extreme temperature PLASKOLITE acrylic sheet can be cut with a vari-
fluctuations can reform flat sheet as it can expand or ety of equipment. The selection of blades is critical
contract. with regards to the quality of the edge finish.
A-frames or special racks can be used to store Table, and Panel saws are the best options for
sheet vertically. Construct the racks allowing the high volume straight cuts. Material can be stacked
acrylic to lean approximately 10°. to cut several sheets at one time. When cutting,
HANDLING the saw blade should protrude through the sheet
approximately 1/4” (See Fig. 3). Saw blades, specifi-
PLASKOLITE acrylic sheet is covered with a poly-
cally designed for cutting acrylic sheet, are commer-
ethylene film or paper masking for protection during
cially available.
storage and fabrication. Avoid sliding sheets across
work surface debris. Chips and dirt can penetrate the
masking, scratching the sheet.
MASKING REMOVAL
When removing the film and/or paper masking
from the acrylic, it is best to start at a corner and peel
away from the sheet. If removal is difficult, combine
50% rubbing alcohol with water in a squirt bottle;
begin spraying at the edges as you pull away from
the sheet.
CLEANING Figure 3
*Guard removed to show
Clean PLASKOLITE acrylic sheet with a mild soap proper blade height.
solution, or a commercially available plastic cleaner,
such as PLASKOLITE PLASTIC CLEANER, and a lint CIRCULAR SAW BLADE SPECIFICATIONS (See Fig. 4):
free cloth. To remove grease, oil, or tar deposits, use Rake angle 0 -10°
hexane or kerosene, followed by a soap solution. Clearance angle 10-15°
Avoid cleaners containing ammonia or alcohol. Blade teeth 80 per 10” blade
NEUTRALIZING STATIC ELECTRICITY Blade
Diameter RPM
PLASKOLITE acrylic sheet can be neutralized with
6” 6400
an anti-static cleaner such as PLASKOLITE PLASTIC
8” 5000
CLEANER, or ionizing air guns, and bars.
10” 4000
12” 3000
CUTTING/MACHINING
14” 2800
16” 2400
SCRIBING & BREAKING
Tooth design (See Fig. 5)
For PLASKOLITE acrylic sheet up to 1/4” thick, Band, scroll, and sabre saws are best for cutting
score repeatedly along a straight edge with a plastic intricate shapes and curves. Again, blade
6
Circle routers can cut round parts by securing
Rake the acrylic sheet to a turntable, then rotating the
sheet around the stationary router.
Computer Numerically Controlled (CNC) rout-
ers are used for high volume, intricate, precise acrylic
parts. The part is designed on a CAD/CAM system
and geometry is programmed directly into the CNC
Clearance
machine. Many of the variables; feed rate, RPM, bit
Figure 4 angle
diameter, depth of cut are adjustable for optimum
cutting performance.
Carbide CNC laser cutters are used to cut virtually any
teeth
shape part from PLASKOLITE acrylic sheet. This form
of cutting produces a clean, polished edge without
saw chips. It is well suited for cutting small intricate
parts that are difficult to hold down with other cut-
Figure 5
ting processes. Paper masked, or sheet with 3 mil
laser cuttable film perform best for this operation.
selection and proper feed rate is important to minimize
MACHINING
melting or chipping. These saws are excellent for cre-
ating templates for vacuum or hand routing, and trim-
Many methods are used to produce a desirable
ming off excess scrap material.
edge finish.
Routers are one of the most versatile pieces of
Shapers and table routers can machine square,
equipment available to trim PLASKOLITE acrylic sheet.
beveled, bull nose, ogee, and other decorative edges
Bit selection is important, and tools specifically designed
(See Fig. 7).
to rout acrylic are commercially available. Use a down-
ward spiral router bit to prevent masking from fraying.
Routers produce a high quality machined edge, ready
for finishing, provided the following formulas are fol-
lowed:
Chip Load = Feed Rate/(RPM X # cutting edges)
Feed Rate = RPM X # cutting edges X chip load
Speed (RPM) = Feed Rate/(# cutting edges X chip Figure 7
Table routing a
load)
beveled edge.
Hand routers are best used for low volume work. Jointers are used to square and prepare edges
With a bearing-mounted, flush trim bit, the router can for cementing or hand finishing. Multiple sheets can
trim around a clamped template. be stacked to increase efficiency (See Fig. 8).
Pin, table and vacuum routers (hand routers
mounted under a table) are more convenient to rout
around intricately shaped templates (See Fig. 6).
Figure 8
Figure 6
Acrylic sheet vacuumed to a template Edge finishing machines with diamond cutting
with a foam rubber gasket between. wheels, produce an edge with a polished look,
excellent for cementing.
7
Mills can be used to create precisely machined designed with proper geometry for cutting acrylic
parts. sheet.
Use proper and constant feed rates, and RPMs.
DRILLING To prolong tool/blade life, apply the fastest feed rate
that gives a satisfactory edge.
Drilling holes is performed best on a drill press
Eliminate vibration of the acrylic sheet through
with commercially available plastic cutting drill bits.
clamping or other hold-down methods.
Guidelines for drilling include:
Align all fences and tables parallel to the cutting
Drill bit Speed
device.
Diameter (RPM)
Machine PLASKOLITE acrylic sheet with a
1/8” 3500
conventional cut rather than a climb cut.
3/16” 2500
Machine off as little acrylic as possible. Two
1/4” 1800
passes may be necessary for thicker acrylic; one to
3/8” 1200
rough out the part, then a final skin cut. For jointers
1/2” 900
and shapers, trim a maximum of 1/32” per pass.
5/8” 700
When necessary, direct compressed air or an
atomized spray of a water soluble coolant toward
The bit should enter the PLASKOLITE acrylic sheet
the tool/blade.
at a slow feed rate, then a steady rate producing two
If all of the above suggestions are followed, heat
continuous spiral chips, finally exiting through the
buildup will be held to a minimum, melting and
acrylic slowly, eliminating chipping.
chipping should not occur, and the edges of the
To reduce heat build up, and removal of material,
PLASKOLITE acrylic sheet will be ready for finishing
peck feeding may be necessary when drilling thick
or further fabrication.
acrylic sheet.
Place a scrap piece of acrylic or plywood beneath
ANNEALING
the sheet to be drilled. This will eliminate chipping
as the bit passes through. After all cutting and machining, internal stresses
Standard twist drill bits can be used, provided occur. To reduce the possibility of crazing, (small
modifications to the bit are performed. These hairline fissures) during cementing, bending, and
modifications will allow the bit to scrape rather than forming, annealing is recommended.
cut through the acrylic sheet (See Fig. 9). Heat PLASKOLITE acrylic sheet for 5 to 6 hours
at 130 to 150°F in a forced air oven. Cool the sheet
60-90° slowly to at least 110°F.
FINISHING
Grind small flats
along cutting edge
SCRAPING
Scrapers are sharp tool steel devises used to
eliminate machining marks and ease sharp edges
(See Fig. 10).
Standard Modified
Twist Drill Bit
Figure 9
Drill Bit
CUTTING/MACHINING TIPS
For optimum cutting and machining quality,
certain guidelines should be followed.
Always use sharp tools/blades reserved for
cutting acrylic sheet. Figure 10
Whenever possible use tools/blades specifically
8