Acrylic Sheets - Frequently Asked Questions

Are you considering using acrylic sheets for your next DIY project? Whether you're a crafting enthusiast, home improvement hobbyist, or professional designer, acrylic sheets offer versatility and durability that few other materials can match. To help you make informed decisions, we've compiled this comprehensive guide addressing the most common questions about acrylic sheets.

Basic Information

1. What exactly are acrylic sheets?

Acrylic sheets (also known as PMMA or by the brand name Plexiglas®) are transparent thermoplastic sheets made from polymethyl methacrylate. They're a lightweight, shatter-resistant alternative to glass with excellent optical clarity, weather resistance, and durability.

2. What's the difference between acrylic and plexiglass?

There is no difference! Plexiglass is simply a brand name for acrylic sheets, similar to Kleenex, which is a brand name for facial tissues. All plexiglass is acrylic, but not all acrylic is branded as Plexiglass®.

3. How does acrylic compare to glass?

Acrylic is:

  • Half the weight of glass
  • 10-20 times more impact-resistant
  • More transparent (92% light transmission vs. 90% for glass)
  • Easier to cut and fabricate
  • Less likely to shatter (it cracks instead)
  • More flexible
  • Better insulator
  • Less expensive for larger applications

Glass, however, is more scratch-resistant and heat-resistant than acrylic.

Why does my 1/8" acrylic sheet seem to be smaller than 1/8"?

Many acrylic manufacturers produce their sheets to metric standards but label them with approximate imperial measurements for the US market. For example, what's sold as "1/8 inch" acrylic is actually 3.0mm (0.118"), which is slightly thinner than a true 1/8" (0.125"). This small difference can be important for precision projects. Below is a conversion chart showing the marketed sizes versus the actual measurements:

Marketed Actual
1/32" 0.8mm / 0.030"
1/16" 1.5mm / 0.060"
1/8" 3.0mm / 0.118"
3/16" 4.5mm / 0.177"
1/4" 5.6mm / 0.220" or 6.0mm / 0.236"
3/8" 9.0mm / 0.354"
1/2" 12.0mm / 0.472"
3/4" 18.0mm / 0.708"
1" 24.0mm / 0.944"

4. What thicknesses do acrylic sheets come in?

Usually, acrylic sheets are available in thicknesses ranging from 1mm (0.04") to 25mm (1"). The most popular thicknesses for DIY projects are 3mm (1/8") and 6mm (1/4").

Working with Acrylic

5. Can I cut acrylic sheets at home?

Yes! Acrylic can be cut using several methods:

  • For straight cuts: score-and-snap method with a plastic scoring tool
  • For precise cuts: a table saw with a fine-toothed blade, jigsaw, or circular saw
  • For intricate designs: laser cutter (for professional results)
  • For thin sheets (up to 3mm): strong scissors or a utility knife

Always wear safety equipment and remove the protective film only after cutting.

6. How do I prevent acrylic from cracking when drilling?

To prevent cracking:

  • Use sharp drill bits designed for plastic or acrylic
  • Drill slowly with minimal pressure
  • Support the acrylic sheet well on both sides
  • Start with a small pilot hole and gradually increase the size
  • Use water or a specialized acrylic lubricant to keep the drill bit cool

7. What's the best way to bend acrylic?

Acrylic can be heat-bent using:

  • Strip heaters (line benders) for precise, straight bends
  • Heat guns for gentle curves (heat evenly until pliable)
  • Ovens for larger pieces (heat to approximately 160°C/320°F)

Never force cold acrylic to bend as it will crack or break.

8. How do I glue acrylic sheets together?

The best methods include:

  • Acrylic cement or solvent-based adhesives for invisible, strong bonds. Acrylic pieces can be bonded together with liquid solvent cements such as Weld-On #3 and #4 or thickened solvents such as Weld-On #16 or Craftics #33.
  • Double Sided Adhesive Sheets
  • Special acrylic glue for gap-filling applications
  • UV-curing adhesives for clear bonding
  • Avoid standard super glue, epoxy, or white glue for permanent applications

Care and Maintenance

9. How do I clean acrylic without scratching it?

Clean acrylic with:

  • Mild soap and water solution
  • Microfiber cloth (never paper towels)
  • Commercial plastic cleaners specifically designed for acrylic
  • Avoid ammonia-based products (like Windex), alcohol, and abrasive cleaners

10. How do I remove scratches from acrylic?

For light scratches:

  • Use specialized acrylic polish or plastic polish
  • Try automotive polishing compound (fine grit)
  • Wet sand progressively with fine-grit sandpaper (1500 to 2000 grit)
  • Buff with a clean, soft cloth

Deep scratches may require professional refinishing.

11. Does acrylic yellow over time?

Quality cast acrylic sheets have excellent UV resistance and should not yellow significantly for 7-10 years in outdoor applications. Extruded acrylic may yellow more quickly. UV-protected acrylic provides even better resistance to yellowing.

Project-Specific Questions

12. What thickness should I use for a fish tank or aquarium?

For DIY aquariums:

  • Up to 10 gallons: minimum 6mm (1/4")
  • 10-30 gallons: minimum 10mm (3/8")
  • 30-75 gallons: minimum 12mm (1/2")
  • 75+ gallons: consult a professional

Remember to calculate water pressure and support needs for your specific dimensions.

13. Is acrylic food safe?

Acrylic sheeting as a material generally does not affect most foods. However, except for special food grade sheets, it is not certified food safe and not recommended for uses where it is in contact with food. Look for acrylic sheets that comply with FDA regulations for food contact. Avoid using solvents or adhesives on surfaces that will contact food.

14. Can acrylic be used outdoors?

Absolutely! Acrylic has excellent weather resistance. For outdoor projects:

  • Choose UV-stabilized acrylic for long-term sun exposure
  • Allow for thermal expansion in your design
  • Use flexible mounting methods
  • Clean regularly to prevent dirt buildup

15. What's the weight capacity of acrylic shelving?

The weight capacity depends on thickness, span, and support:

  • 3mm (1/8"): Light items only (photos, small decorations)
  • 6mm (1/4"): 5-10 lbs per square foot with proper support
  • 10mm (3/8"): 15-20 lbs per square foot
  • 12mm (1/2"): 25+ lbs per square foot

Always use shorter spans and multiple supports for heavier loads.

16. Can I paint acrylic sheets?

Yes! For best results:

  • Clean thoroughly and lightly sand for adhesion
  • Use acrylic-compatible primers
  • Apply acrylic-based paints or special plastic paints
  • Consider spray paint for even application
  • Allow proper drying time between coats

For reverse painting (for signage), paint the back side of clear acrylic.

17. How heat-resistant is acrylic?

Acrylic begins to soften around 160°C (320°F) and should not be used for applications that reach temperatures above 80°C (176°F) for extended periods. For high-temperature applications, consider polycarbonate as an alternative.

Technical Questions

18. What's the difference between cast and extruded acrylic?

Cast and extruded acrylic are manufactured in different ways using the same components. Either will be acceptable in many use cases, however, there are some important differences between the two:

Cast acrylic:

  • Higher optical quality and superior surface quality
  • Better chemical resistance
  • Easier to machine, cut cleanly, and glue
  • More expensive
  • Available in thicker sheets
  • Turns matte white when laser engraved, creating more contrast
  • Harder surface that's slightly more scratch-resistant
  • Thickness tolerance can vary by +/- 10% or more
  • Cuts with cleaner edges when laser cutting

Extruded acrylic:

  • More economical
  • Slightly less optical clarity
  • Lower chemical resistance
  • May have more internal stress
  • Great for laser cutting with flame-polished edges when using higher power
  • Better thickness tolerance (+/- 5% or better across the sheet)
  • Easier to flame polish due to lower forming temperature
  • Does not change colour when laser-engraved
  • Expands/shrinks differently relative to extrusion direction during thermoforming

19. Is acrylic environmentally friendly?

Acrylic is:

  • 100% recyclable (though specialized facilities may be required)
  • Long-lasting, reducing replacement needs
  • Free from BPA and other harmful plasticizers
  • Energy-efficient as a building material (good insulation)
  • Less resource-intensive to manufacture than glass

20. How strong is acrylic compared to other plastics?

Acrylic offers excellent tensile strength compared to many plastics:

  • Stronger than polystyrene and PVC
  • Not as strong as polycarbonate or ABS
  • Much more rigid than flexible plastics like polyethylene
  • Good impact resistance (17 times more impact-resistant than glass)

21. Does acrylic block UV light?

Standard acrylic blocks about 98% of UV-B rays but allows some UV-A rays to pass through. Special UV-filtering acrylic is available that blocks virtually all UV radiation, making it ideal for museum displays, art framing, and conservation purposes.

22. Can acrylic be recycled?

Yes, acrylic is a Type 7 plastic that can be recycled through specialized facilities. Clean, single-type acrylic waste can be melted down and reformed into new products. Contact local recycling centers to determine if they accept acrylic materials.

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