The Acrylic Fabrication Process: A Clean, Detail-Oriented Approach
Acrylic (often referred to as Plexiglas) fabrication is a meticulous manufacturing process that yields high-quality, defect-free products. Unlike injection-molded pieces, hand-fabricated acrylic eliminates relief marks and blue haze, resulting in a polished, professional finish.
The process consists of four main steps: Cut, Bend, Glue, and Polish.
1. Cut
The first step involves cutting acrylic sheets into the required sizes and shapes. Precise cutting ensures a strong foundation for the final product.
2. Linear Bend
Once cut, the pieces are bent into the desired shapes.
Heat Strip Bending:
Acrylic pieces are heated slightly above heat strips. The heat softens the acrylic along thinner grooves, making it malleable for bending according to the blueprint.Molded Bending:
For parts requiring specific radii, heat strips are insufficient. Instead, a mold is created, and the acrylic panel is softened in an oven using the mold. Although more time-consuming, this method ensures precise results.
3. Glue
Next, the acrylic pieces are joined together.
- A precise, thin layer of acrylic glue is applied to the required areas, then held in place using clamps and weights for proper drying.
- Accurate application is crucial, as poorly glued joints can result in defects.
- Quality Indicator: High-quality glue joints are bubble-free, ensuring durability and an aesthetic finish.
4. Polish
The final step is polishing, which enhances the acrylic’s appearance and clarity.
Flame Polishing:
By using a very hot flame, the surface of the acrylic slightly melts, allowing surface tension to smooth it out. This produces a clear finish but may increase susceptibility to microscopic cracks (creasing) when cleaned with solutions containing alcohol or ammonia (e.g., Windex).Advanced Polishing Methods:
For superior quality, diamond-edge polishing and sand/buff polishing are employed. Although more time-intensive, these techniques yield higher-quality results with reduced risk of creasing.
Custom Acrylic Fabrication Capabilities
This process allows us to create a variety of products, including table tents, small and large displays, and mixed-material displays (wood and acrylic).
At Desert Star Plastics, we also offer vacuum forming, CNC machining, laser cutting, and engraving—all done in-house.
For museum-quality displays, we provide bubble-free glue joints to meet the highest standards.
Have a project in mind?
Contact us at 602-340-1236 or orders@desertstarplastics.com. You can also request a quote by filling out the form here.
