Cast acrylic sheets are a favorite among artists, architects, makers, and sign fabricators. They’re stronger and lighter than glass, offer more color and transparency options than wood or metal, and are easy to work with—perfect for laser cutting, bonding, and shaping.
In this guide, Canal Plastics Center combines expert insights from top manufacturers like PT Margacipta, Evonik, and Chemcast to help you achieve clean, professional results on every project.
1. Sheet Sizes & Thicknesses
Cast acrylic is available in a wide range of sizes and thicknesses. At Canal Plastics, we stock sheets from 0.040" up to 4" thick, and offer three convenient options for every type of project.
Pre-Cut Acrylic Blanks
Our precut sheets range from 2" x 2" samples up to 24" x 48", designed to fit most laser beds.
Common sizes include:
6" × 12" | 12" × 12" | 12" × 18" | 12" × 24" | 18" × 24" | 18" × 32" | 24" × 24" | 24" × 36" | 24" × 48"
Size tolerance: ± 1/8" for most sheets, or ± 1/4" for specialty pearl patterns.
All are available for same-day pickup or UPS shipping.
Full Sheets
We stock clear cast acrylic in standard full-sheet sizes, available for pickup, local delivery, or LTL freight.
| Nominal Thickness | Actual (in) | Max Width (in) | Max Length (in) |
|---|---|---|---|
| 0.040" | 0.040 | 36 | 72 |
| 1/16" | 0.060 | 48 | 72 |
| 1/8" | 0.118 | 72 | 120 |
| 3/16" | 0.177 | 72 | 120 |
| 1/4" | 0.220 | 72 | 120 |
| 3/8" | 0.354 | 72 | 120 |
| 1/2" | 0.472 | 72 | 120 |
| 3/4" | 0.708 | 72 | 120 |
| 1" | 1.000 | 72 | 120 |
| 1.25" | 1.250 | 48 | 96 |
| 1.5" | 1.500 | 48 | 96 |
| 2" | 2.000 | 48 | 96 |
| 2.5" | 2.500 | 48 | 96 |
| 3" | 3.000 | 48 | 96 |
Note: Most colored cast acrylic sheets max out at 48" × 96".
Custom Cut-to-Size
Need precision cuts? We offer saw-cut, laser-cut, or CNC-cut acrylic to your exact dimensions.
Email us your specs and we’ll send a quick quote.
Understanding Thickness Variation
Cast acrylic is made by cell casting, where liquid monomer (MMA) is cured between two polished glass plates.
This process creates the sheet’s clarity and glossy finish, but also natural thickness variations as the material cools.
Typical tolerance is ±15%.
For example, a nominal ¼" sheet (0.220") may range from 0.190"–0.253" thick.
Pro Tip:
When fabricating tanks, edge-bonding displays, or CNC-cut parts, measure each sheet before cutting—especially thicker gauges.
2. Cutting & Machining Acrylic
You can cut acrylic with common tools, but technique matters.
Sawing:
Use fine-tooth carbide blades designed for plastics. Keep the protective masking on to avoid scratches.
Laser Cutting:
Produces clean, polished edges. Use low power and slow speed for best clarity.
Drilling:
Use acrylic drill bits—they have a sharper tip angle than metal bits to reduce cracking.They are different than standard metal drill bits.
Explore our Pro Series Plastics Drill Bits →
Routing:
Ideal for edge finishing and pattern work. Use high-speed up-cut bits for 1/8" and thicker sheets. Maintain steady feed rates to prevent melting.
3. Laser Cutting Cast Acrylic (Without Cracks or Crazing)
Laser cutting is precise, but can stress the material if done incorrectly.
Laser Cutting Tips:
Leave the protective film on to avoid burning.
Use just enough power—too much heat causes edge cracking.
Thicker sheets = slower speed.
Always test first!
What should my setting be?
Well they depend on what you're cutting, masking, extruded vs cast, your design, your laser CO2 tubes (make sure they're full), ventilation, your laser beam alignment, laser bed calibration etc. Other places have put charts in place, but we prefer to test first. Remember - even if you're cutting the same material i.e. 1/8" clear cast blanks - different manufacturers use different resin and the surface hardness will vary. This leads to slight but important differences of how they cut and how the edge looks after cutting.
After Cutting:
Test your pieces. Laser cutting produces stress and can lead to crazing. Also the joints will not be too strong. The best method would be to anneal the laser cuts before cementing them, but not everyone has the means to anneal acrylic pieces. At the very least make sure you sand the edges before cementing them.
4. Bonding & Gluing Acrylic
You can glue acrylic with special solvent-based adhesives. The technique depends on the fit.
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Tight fit? Use thin solvent like Weldon #3 or #4 (capillary method). Explore acrylic cements →They are listed under the solvent cements section of our accessories.
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Small gaps? Use thicker cement like Weldon #16.
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Dip/bath bonding? Best for edges only. Clean and flame-polish for strongest bonds.
Always clean and sand edges before bonding—especially laser-cut pieces.
5. Bending & Forming Acrylic
Heat acrylic to reshape it for displays, covers, or enclosures.
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Line bending: Use a strip heater at ~320°F (160°C).
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Thermoforming: Heat to 284–356°F (140–180°C), then form into a mold.
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Expect 1–2% shrinkage after forming.
6. Polishing & Edge Finishing
Want crystal-clear edges? Try these:
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Flame Polishing: For straight cuts only. Use hydrogen/oxygen torch. Be careful - not recommended for beginners.
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Buffing: Use a cotton wheel and polish (like rouge). Buffing Option →
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Wet Sanding: Go from 400 to 1200 grit, then polish for glass-like clarity.
7. Cleaning & Maintenance
Keep your acrylic looking new:
Use: Mild soap, water, or anti-static acrylic cleaner.
Avoid: Ammonia-based cleaners (like Windex)—they cause surface damage over time.
Light scratches: Use Novus 1, 2, or 3 polish or a similar scratch remover.
8. Physical Properties of Cast Acrylic
| Property | Typical Value | ASTM Test |
|---|---|---|
| Light Transmission | ~92% | D1003 |
| Tensile Strength | 9,500–9,600 psi | D638 |
| Flexural Strength | 15,000–16,000 psi | D790 |
| Service Temperature | Up to 176°F | D648 |
| Refractive Index | 1.49 | D542 |
Conclusion
Cast acrylic is strong, beautiful, and easy to shape or glue with the right techniques. Whether you’re designing signage, laser-cutting models, or fabricating custom displays, following these guidelines ensures professional results every time.
🛒 Need help choosing the right sheet?
Explore our Acrylic Sheet Collection →