OPTIX® ACRYLIC SHEET

FABRICATION GUIDE
 Table of Contents
Page

Introduction / Contact Information . . . . . . . . . . . . . . . . 3

Typical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

OPTIX Product Selection Guide . . . . . . . . . . . . . . . . . . . . 6

Chemical Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . 9-10

Fabrication & Machining . . . . . . . . . . . . . . . . . . . . . . . . 11-17

Thermoforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-23

Bending, Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-27

Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29

Mechanical Fastening . . . . . . . . . . . . . . . . . . . . . . . . . 30-33

Painting, Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-37

Handling & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . 38-40

Suggested Vendors . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-42

This manual is a general guide for working with PLASKOLITE OPTIX® sheet. Because actual results vary with
differences in operating conditions, thickness, color, and composition of the OPTIX sheet, nothing contained
herein can be construed as a warranty that PLASKOLITE’s OPTIX sheet will perform in accordance with
these general guidelines.
Important Notice: Our recommendations, if any, for the use of this product are based on tests believed to be
reliable. The greatest care is exercised in the selection of raw materials and in the manufacturing operations.
However, since the use of this product is beyond the control of the manufacturer, no guarantee or warranty
expressed or implied is made as to such use or effects incidental to such use, handling, or possession of the
results to be obtained, whether in accordance with the directions or claimed so to be. The manufacturer
expressly disclaims responsibility. Furthermore, nothing contained herein shall be construed as a recom-
mendation to use any product in conflict with existing laws and/or patents covering any material or use.
Anyone experiencing problems fabricating OPTIX sheet should refer those questions to the PLASKOLITE
Inside Sales Department. This manual does not constitute an offer to sell by the Company. The Company
sells ONLY under its current Terms and Conditions of Sale, which appear on its Acknowledgements and
invoices. A current copy of the Company’s Terms and Conditions of Sale will be supplied upon request.
The details provided are believed to be accurate at the time of publication; however, no description is a
warranty that the product is suitable for any application. THE COMPANY MAKES NO WARRANTIES, AND
UNDERTAKES AND ACCEPTS NO LIABILITIES, EXCEPT ONLY AS SET FORTH IN ITS CURRENT TERMS
AND CONDITIONS OF SALE.

2
Introduction
ACRYLIC CLASSIFICATIONS
PLASKOLITE is uniquely positioned to manufacture all
three types of acrylic for any of your applications.
We offer excellent solutions for all acrylic projects.

Continuously processed (extrusion and OPAT)

Acrylic sheet made by extrusion process or specialized
PLASKOLITE single pass technology. Product has low molecular
weight, optical clarity and good craze resistance.

Continuous cast
Acrylic sheet made by polymerizing liquid monomer into
PMMA between two highly polished, stainless-steel belts. This
is a unique process by which sheet is produced on continuous
moving belts. It combines the best properties of extruded
acrylic sheet with cell cast sheet. Excellent thickness control,
high molecular weight, and better craze resistance.

Cell cast
Acrylic sheet made by pouring liquid MMA monomer between
two glass plates surrounded by gasket. They are placed into
an oven to complete the process. Product has the highest
molecular weight, highest hardness, and best craze resistance
of the three types listed.

Contact Technical Service Group with additional questions:

800.848.9124
[email protected]
3
 Typical Properties
OPTIX® Acrylic Sheet OPTIX® SG Acrylic Sheet
Property Test Method Units Values Property Test Method Units Values
PHYSICAL
PHYSICAL
Specific Gravity / Relative Density ASTM D792 – 1.19 Specific Gravity ASTM D792 – 1.15 - 1.19
Optical Refractive Index ASTM D542 – 1.49 Light Transmission- total ASTM D1003 % 90 - 92
Light Transmission - Total ASTM D1003 % 92 Light Transmission- haze ASTM D1003 % <3
Light Transmission - HazeA STM D1003 % <2 Water Absorption ASTM D570 % 0.4
Sound Transmission ASTM E90 / E413 dB 27 Mold Shrinkage ASTM D955 Mils/in 2-6

Water Absorption ASTM D570 % 0.4 MECHANICAL

Tensile Strength ASTM D638
Mold Shrinkage ASTM D955 mils/in 2-6
SG psi 11,030
MECHANICAL SG05 psi 8,000
Tensile Strength ASTM D638 psi 11,030 SG10 psi 5,600
Tensile Elongation – Max. ASTM D638 psi 5.8 Tensile Modulus of Elasticity ASTM D638
Tensile Modulus of Elasticity ASTM D638 psi 490,000 SG psi 490,000
SG05 psi 340,000
Flexural Strength ASTM D790 psi 17,000
SG10 psi 250,000
Izod Impact Strength - Notched ASTM D256 ft-lb./in 0.4 Flexural Strength ASTM D790
Tensile Impact Strength ASTM D1822 ft-lb./in2 20 SG psi 17,000
Abrasive Resistance – Change in Haze SG05 psi 12,000
10 cycles ASTM D1044 Haze % 11.2 SG10 psi 8,300
50 cycles ASTM D1044 Haze % 24 Izod Impact Strength – Notched ASTM D256
200 cycles ASTM D1044 Haze % 24.9 SG ft-lb./in 0.4
SG05 ft-lb./in 0.7
Rockwell Hardness ASTM D785 – M-95
SG10 ft-lb./in 1.1
THERMAL Rockwell hardness ASTM D785
Maximum Recommended SG – 95
Continuous Service Temperature – °F 170-190 SG05 – 68
Softening Temperature ASTM D1525 °F 210-220 SG10 – 46
Deflection Temperature THERMAL
@ 264 psi (1.8 MPa) ASTM D648 °F 203 Maximum Recommended
Deflection Temperature Continuous Service Temperature – °F 170-190
@ 66 psi (0.45 MPa) ASTM D648 °F 207 Softening Temperature – °F 210-220

Coefficient of Linear Thermal Expansion ASTM D696 in/in/°F 3.0 x 10-5 Deflection Temperature
@ 264 psi (1.8 MPa) ASTM D648
Thermal Conductivity ASTM C177 Btu-ft/ft2/hr/°F 0.075
SG °F 203
Flammability (Burning Rate) ASTM D635 in/min 1.0 SG05 °F 194
Flammability
*Typical UL
properties are not intended for specification 94
purposes. – HB SG10 °F 185
Smoke Density Rating ASTM D2843 % 3.4 Coefficient of Thermal Expansion ASTM D696 in/(in-°F ) x 10-5 3.0 - 5.0
Self-Ignition Temperature ASTM D1929 °F 833 Flammability (Burning Rate) ASTM D635
SG in/minute 1.0
Flame Spread Index ASTM E84 – 115
SG05 in/minute 1.25
Smoke Developed Index ASTM E84 – 550
SG10 in/minute 1.97
Flammability UL 94 – HB
Smoke Density Rating ASTM D2843
SG % 3.4
SG05 % 8.5
SG10 % 16.5

DURAPLEX® Sheet Self-Ignition Temperature ASTM D1929 °F 833

Property
Test Method Units Duraplex Duraplex Duraplex Duraplex
30% 50% (SG05) 70% 100% (SG10)
PHYSICAL
Specific Gravity ASTM D792 – 1.18 1.17 1.16 1.15
Light Transmission - Total ASTM D1003 % 92 92 90 90
Light Transmission - Haze ASTM D1003 % 2 2 <3 <3
Water Absorption ASTM D570 % 0.3 0.3 0.3 0.3
Mold Shrinkage ASTM D955 mils/in 3-6 3-6 3-6 3-6
MECHANICAL
Tensile Strength ASTM D638 psi 9,000 8,000 7,100 5,600
Tensile Modulus of Elasticity ASTM D638 psi 376,000 340,000 304,000 250,000
Flexural Strength ASTM D790 psi 13,690 12,000 10,610 8,300
Izod Impact Strength - Notch ASTM D256 ft-lb./in 0.6 0.7 0.9 1.1
Rockwell hardness ASTM D785 – M-78 M-68 M-59 M-46
THERMAL
Deflection Temperature
@ 264 psi (1.8 MPa) ASTM D648 °F 198 194 190 185
Coefficient of Thermal Expansion ASTM D696 in/in/°F 3.5 x 10-5 4 x 10-5 4.5 x 10-5 5 x 10-5
Flammability (Burning Rate) ASTM D635 in/min 0.85 1.25 1.53 1.97
Flammability UL 94 – HB HB HB HB
Smoke Density Rating ASTM D2843 % 5.2 8.5 11.5 16.5

4 Self-Ignition Temperature ASTM D1929 °F >850 >850 >850 >850

Typical Properties
OPTIX® L Continuous Cast Acrylic Sheet
Property Test Method Units Values
PHYSICAL
Specific Gravity ASTM D792 – 1.19
Optical Refractive Index ASTM D542 – 1.49
Light Transmission- total ASTM D1003 % 92
Light Transmission- haze ASTM D1003 % <1
Water Absorption ASTM D570 % 0.2
MECHANICAL
Tensile Strength ASTM D638 psi 11,000
Tensile Modulus of Elasticity ASTM D638 psi 465,000
Flexural Strength ASTM D790 psi 14,700
Flexural Modulus of Elasticity ASTM D790 psi 461,000
Izod Impact Strength - Milled Notch ASTM D256 ft-lb./in 0.32
Compressive Strength ASTM D 695 psi 83,300
Shear Strength ASTM D732 psi 11,200
Rockwell hardness ASTM D785 – M-100
THERMAL
Maximum Recommended
Continuous Service Temperature – °F 175
Deflection Temperature @ 264 psi (1.8 MPa) ASTM D648 °F 200
Coefficient of Linear Thermal Expansion ASTM D696 in/in/°F 3.5 x 10-5
Thermal Conductivity ASTM C177 Btu-ft/ft2/hr/°F 0.12
Flammability (Burning Rate) ASTM D635 In/min 1.18
Flammability UL 94 – HB
Smoke Density Rating ASTM D2843 % 13.5
Self-Ignition Temperature ASTM D1929 °F 750
Flame Spread Index ASTM E84 – 110
Smoke Developed Index ASTM E84 – 530
ELECTRICAL
Dielectric Constant @ 1 KHz ASTM D150 – 3.0
Dielectric Constant @ 1 MHz ASTM D150 – 2.7
Dielectric Strength ASTM D149 V/mil 354
Volume Resistivity ASTM D257 Ohms/cm >3.91 x 1015

OPTIX® Cell Cast Acrylic Sheet

Property Test Method Units Values
PHYSICAL
Specific Gravity / Relative Density ISO 1183-1 – 1.19
Haziness ISO 14782 % 0.5
Refractive Index ISO 489 – 1.49
Water Absorption ISO 62 % 0.5
MECHANICAL
Tensile Strength ISO 527-2/1B/5 MPa 78.1
Tensile Elongation ISO 527-2/1B/5 % 4.2
Tensile Modulus of Elasticity ISO 527-2/1B/I MPa 3065
Bending Strength ISO 178 MPa 127.8
Bending Modulus ISO 178 MPa 3610
Impact Strength
Izod - Unnotched ISO 180/U1 kJ/kg 14.8
Izod - Notched ISO 180/A1 kJ/kg 1.7
Charpy - Unnotched ISO 179-1 FU kJ/kg 19.8
Charpy - Notched ISO 179-1 EA kJ/kg 1.4
Rockwell Hardness ISO 2039-2 M scale 103
THERMAL
Vicat Softening Temperature ISO 306 °C min. 110
Coefficient of Linear Thermal Expansion ISO 11359-2 mm/m/°C 7 x 10-5
Bending Temperature Under Load ISO 75-2/A °C 104.6
Size Change with Heating Annex A % 2.4

5
 OPTIX Key Product Typical
Grade Features Applications
General Purpose* Clear and colors, weather resistant, good alternative to glass, Lighting, signage, picture framing, glazing,
easy to fabricate and form transportation, POP display
95* Translucent matte finish one side, resistant to smudge and Room/office partitions, pantry/cupboard
fingerprints, easy to fabricate and form doors, signage and POP displays
99* Ultra-light matte, minimizes unwanted glare, shatter resistant Ideal for glazing, signage and POP displays
Non-glare Non-glare translucent heavy matte, shatter resistant Signage, silk-screening and POP displays
Heavy Matte* and lightweight
Non-glare Non-glare translucent light matte, shatter resistant Interior/exterior glazing, signage,
Light Matte* and lightweight silk-screening and POP displays
Patterned* Adobe and Haircell patterns, translucent, interior and Shower doors, displays, indoor/outdoor
exterior applications furniture and home furnishing
Duraplex* 3 levels of impact strengths (low, medium, high), superior optical Indoor and outdoor displays, skylights,
properties and UV stability, easy to fabricate and form signage, replacement windows
Thin* Crystal clear, strong and engineered for electronic applications Electronics
Thick* Crystal clear, impact resistant, clear and colors POP displays, furniture, architectural glazing
NB* Block traffic noise, UV stable, extremely weatherable, Highway noise barriers
high impact strength, high clarity
SG* Sheet and reels, excellent forming, high optical clarity and Interior and exterior signages,
superb weatherability, available in 3 impact strengths POP displays, skylights
LD* Superior diffusion, easy to fabricate and form, exceptional Signs, interior and exterior displays
UV stability, visible hot spots eliminated
UVF* Enhanced ultraviolet filtering, absorbs up to 98% of damaging Lighting, POP displays, picture frames,
UV, high optics, weather and impact resistant artwork, glazing, transportation, signage
LED Lighting* Superior optics, easy to fabricate and form, exceptional Interior and exterior signage, lighting
UV stability fixtures, retail displays
LED Lighting* High impact strength, superior optics, easy to fabricate Interior and exterior signage, lighting
Impact Modified and form, exceptional UV stability fixtures, retail displays,
DA* Optimal adhesion of UV curing inks, specially formulated Interior and exterior, signage, graphics,
for printing dry-erase boards
E-DA* Abrasion and chemical resistant, optimal adhesion of UV curing Signage, graphics, dry-erase boards
inks, specially formulated for printing, erasable
AMGARD* Antimicrobial protection, half the weight of glass, easy to Protective barriers, office partitions, safety
fabricate and clean enclosures, equipment housings
AMGARD* SR Scratch resistant, antimicrobial protection, chemical resistant, Protective barriers, office partitions, safety
half the weight of glass, easy to fabricate and clean enclosures, interior windows and glazing
L** High clarity, exceptional UV, superior craze and chemical Furniture, cosmetic displays, interior
resistance, easy to fabricate and form partitions, signage
Black/White** Appears black during the day and illuminates white, red, green, Same-sign night or day applications,
blue or other colors at night depending on the color of LEDs used displays, lighting fixtures
Block*** Optimized light transmission, interior or exterior, lightweight Signage, display
Ecoshade** Reflects more than 75% infrared radiation, reduces heat gain Skylights, windows, doors and partitions
and loss
Edge Lit** Light diffusion technology when used with Neon, Fluorescent, ADA compliant signs, display, lighting
and LEDs fixtures, wayfinding, frame signage
Frame** 100% guarantee no black speck contamination, easy to fabricate Framing solutions for museums,
and form, interior/exterior public buildings and private showcases
Museum Filters out 98% damaging UV light, meets museum standards, Exhibit display cases
Grade** 100% guarantee no black specks, superior optics, uniform thickness
MYST** Frost look permanently infused in sheet, maintains frost look Advertising display, corporate identity,
during processing tradeshow exhibits, interior design, POP
display, store fixtures and solid surfaces
UTRAN** Transmits UV light down to 289nm, high gloss surface easy to clean Indoor tanning beds, animal habitats,
and keep sterile, easy to form and is impact resistant greenhouses
6
*Extruded Acrylic **Continuous Cast Acrylic ***Cell Cast Acrylic
 Chemical
Resistance

7
 Chemical Resistance
NO ATTACK ATTACK
Alum, Ammonium Acetaldehyde
Alum, Potassium Acetic Acid
Aluminum Fluoride Acetic Anhydride
Aluminum Sulfate Acetone
Ammonia Gas Alcohol, Amyl
Ammonium Carbonate Alcohol, Butyl
Ammonium Chloride Alcohol, Ethyl
Ammonium Hydroxide Alcohol, Methyl
Ammonium Phosphate Alcohol, Propyl
Ammonium Sulfate Ammonia
Antimony Trichloride Amyl Acetate
Barium Chloride Aniline
Barium Hydroxide Battery Acid (Conc.)
Barium Sulfide Benzaldehyde
Battery Acid (10%) Benzene
Benzoic Acid Butyl Acetate
Boric Acid Butyric, Acid
Calcium Hypochlorite Carbon Tetrachloride
Carbonic Acid Chloroacetic Acid
Citric Acid Chlorosulfonic Acid
Copper Chloride Dimethyl Ether
Detergent Solution Dimethyl Formamide
Diesel Oil Ethyl Acetate
Diethylene Glycol Ethyl Alcohol
Ethylene Glycol Ethyl Chloride
Fatty Acids Ethylene Dichloride
Ferrous Chloride Ethyl Ether
Ferrous Sulfate Formic Acid
Magnesium Sulfate Gasoline
Formaldehyde Hydrofluoric Acid
Glycerin Isopropyl Alcohol
Hydrochloric Acid (10%) Lactic Acid
Hydrogen Sulfide Methyl Ethyl Ketone
Kerosene Nitric Acid (Conc.)
Lubricating Oil Sulfuric Acid (Conc.)
Nickel Chloride Toluene
Nickel Sulfate Xylene
Soap Solution
Sodium Carbonate
Sodium Chloride
Sodium Hydroxide
Sulfuric Acid (10%)
Turpentine
8 Water (Distilled)
 Cleaning
Recommendations

9
 Cleaning Recommendations
OPTIX® cleaning instructions Removing scratches:
Periodic cleaning of OPTIX and OPTIX L sheet is recommended Deep scratches and gouges made by sharp objects such as
to prolong the service life of the material. To minimize the risk keys, screwdrivers and knives cannot be repaired. Fine scratches
of damage, use only compatible cleaners and the correct may be reduced in severity or cosmetically hidden by using
cleaning method. a plastic scratch remover, such as a NOVUS® branded plastic
scratch remover, and a soft flannel pad. When the scratches
General cleaning instructions: have disappeared, remove any remaining cleaner and polish.
» For dust removal; lightly moisten a soft cotton or fine micro For deeper scratches: Use wet super or ultra fine (400 grit
fiber cloth and wipe evenly across the sheet. or higher) sandpaper. Using plenty of water and rinse the
Note: Take special care to wipe gently as dust particles can sandpaper frequently. Buff with a clean muslin wheel and
scratch acrylic. approved polishing compound.
» The material may be cleaned with mild soap solution,
Polishing gloss surfaces:
PLASKOLITE Plastic Cleaner or compatible cleaners, along
with lukewarm water and light pressure of the cleaning cloth. » To protect the gloss surface OPTIX may be polished using
a compatible commercially available plastic polishing
» Rinse with clean water and dry by blotting with a chamois or
compound (e.g., NOVUS®). Apply a thin, even coat with a
soft non-abrasive cloth.
soft non-abrasive cloth. Wipe with a clean damp cloth to
prevent dust particles from forming.
Removing heavy oil, grease and tars:
» Thoroughly pre-rinse with warm water to loosen and wash
away surface residue, grit, and grime
» Gently rub area with a soft non-abrasive cloth and
approved cleaners – Follow manufacturers directions outlined
on their containers.
» Rinse with lukewarm clean water to remove cleaning residue

Removing adhesive-backed labels:

» Vinegar or kerosene will help lift adhesive
» Immediately rinse thoroughly with clear, lukewarm water
» To prevent water spots, dry with a soft cloth

Important reminders:
» Do not clean OPTIX with any cleaners other than those on the
approved, compatible list included in this guide, or those
tested and found compatible.
» Do not use abrasive cleaners
» Do not apply cleaners under direct sunlight or at
elevated temperatures
» Do not use scrapers, squeegees, razors or other sharp
instruments as they may permanently scratch OPTIX
» Dry or gritty cloths may cause scratches on the sheet surface

10
 Fabrication
& Machining

11
 Fabrication & Machining
Cutting Dimensional accuracy
OPTIX® sheet products are easily fabricated using standard The rate at which OPTIX sheet expands is a movement rate
cutting tools. Carbide tipped cutters are recommended for of 0.060˝ per 12 inches of linear dimensions, over a 70°F
circular saws and carbide router bits. Always use properly temperature change. Note: as a general rule, the dimension
sized cutting tools. should always be checked at room temperature.

Cooling Protective masking

Cooling OPTIX sheet can be achieved using compressed air OPTIX sheet comes with protective masking. This film guards
or vortex tube cooled air systems. These systems are clean against surface damage during shipment and handling as well as
to operate and easy to maintain. A mist system uses a water- fabrication. This masking should be left on during fabrication.
soluble oil to provide blade lubrication and cooling. These
Masking cannot withstand direct outdoor exposure for
systems require more maintenance and the sheet will need
prolonged periods and must be removed soon after installation.
to be cleaned after fabrication. Please confirm the oil used is
If not removed, the film will degrade and may become difficult
compatible with OPTIX acrylic sheet.
if not impossible to remove. Storing sheets outdoors is not
TECH TIP: recommend for this reason.

Wear eye protection, and ensure equipment has safety Remove the masking prior to doing any type of heat processing.
guarding. Stock feed rates must be carefully controlled as
an excessive rate causes vibration and may crack the part.

SAWING, DRILLING, MILLING & ROUTING

CIRCULAR SAWING
As shown in the accompanying illustration, use a carbide-tipped, The blade cutting speed should be 5000-6000 ft/min, and the
circular saw blade with triple-chip tooth design, which cuts table saw setup gap (between saw blade and bed) must be kept
clean and lasts longer than high strength steel. Blade is hollow- to a minimum for clean cuts.
ground and slotted for expansion and cooling, with a rake angle
0 - 10°. and a clearance angle of 0 - 15°.

Circular saw blade and cutting Circular saw troubleshooting

Cutting speed (rpm) 5000 - 6000 PROBLEM: Melting or Gummed Edges
4˝ Blade 8 - 10 teeth/inch
SUGGESTED SOLUTIONS:
8 - 10˝ Blades 6 - 8 teeth/inch
1. Increase blade tooth size
2. Reduce saw speed
3. Increase feed rate
4. Use compressed air to cool blade
5. Inspect blade for sharpness
6. Check blade-fence alignment
7. Reduce number of sheets in stack

Carbide PROBLEM: Chipping

Teethd SUGGESTED SOLUTIONS:
1. Decrease blade tooth size
2. Increase saw size
3. Provide better clamping/support for sheet stack
4. Reduce feed rate
5. Check blade and arbor for wobble
Blade 6. Inspect blade for sharpness

12
Fabrication & Machining
BAND SAWING Band saw troubleshooting
Band sawing is preferred for cutting contours and
PROBLEM: Melting or Gummed Edges
irregular shapes.
SUGGESTED SOLUTIONS:
General guidelines: 1. Increase blade tooth size
» Use precision or standard blades for sheet and parts made 2. Reduce saw speed
from thin gauge
3. Use compressed air to cool blade
» Use buttress or skip-tooth blades for sheets thicker than
4. Check blade sharpness
1/8 inch
» Choose band saw blades with generous set to reduce PROBLEM: Chipping
friction and heat buildup SUGGESTED SOLUTIONS:
» Cool the cut junction with air or a water mist
1. Decrease blade tooth size
» Control the feed rate carefully to prevent binding 2. Slow down stock feed rate
and gumming 3. Provide better clamping/support to eliminate vibration
» Use saw guides whenever possible 4. Check blade sharpness

Band saw blade design

Part thickness Tooth type Pitch Band speed

(inch) (teeth/inch) (rpm)
8 - 12 teeth < 1/8 Precision or Standard 8 - 12 2,000
1˝ per inch
1/8 - 1/4 Buttress or Skip Tooth 5-6 1,500
> 1/4 Buttress or Skip Tooth 3-4 1,000

13
 Fabrication & Machining
DRILLING
Drilling holes is performed best on a drill press with commer- To avoid cracking when using a bolt for installation, drilling
cially available plastic cutting drill bits. Standard drill bits can be distance from edge of sheet should be at least 2 times the
used, as long as modifications to the bit are performed to allow diameter of the bolt. The distance from the center of the hole to
the bit to scrape rather than cut through the acrylic sheet. the edge of the sheet should be at least 1.5 times the diameter
» Drill point angles typically range between 60 and 90 degrees of the drilled hole. This will allow adequate space for thermal
expansion and contraction.
» Drilling speeds range between 700 and 3500 rpm, with lower D
speeds for thicker sheets. d
These conditions produce smooth surface holes with smooth
continuous chips. Air or liquid coolants should be used when
possible to reduce heat generated. If the depth of hole exceeds OPTIX sheet
the diameter a coolant should be used for any hole > 0.25˝. In
addition, cold air guns are cleaner to use than liquid coolants,
however the trickle from the liquid coolants result in better hole
finishes. Other compatible solvents are suitable for use. d = Bolt diameter
D = Clearance hole for bolt
TECH TIP: When using standard bits, it is recommended (at least 2 x d)
to place a second substrate on the back side of the sheet A = Distance from hole center
like tape or another section of acrylic for support, so the to edge of sheet (min. 1.5 x D) A
bit doesn’t “blow out” the back when exiting the sheet.
This usually works to prevent cracking.

Flute or Helix Angle – 17°

Flute
Web
Lip Clearance
or Relief Angle “Dubbed-Off”
4°- 8° Lip
Drill
Diameter
Heel Polished Lands
(One-quarter the
width of the Heel)

Point Angle – 60°- 90°

(Angle depends on part thickness)

Common drilling problems and remedies

Description of problem Probable cause Remedy
Hole too large 1. Unequal angle on length of cutting edge 1. Properly regrind drill bit
2. Burr on drill bit 2. Properly regrind drill bit
Rough or burred hole 1. Dull drill bit 1. Regrind properly
2. Improperly ground drill bit 2. Regrind properly
3. Too fast feed 3. Reduce feed
Breaking of drill bit 1. Feed too fast in relation to spindle speed 1. Reduce feed or increase speed
2. Dull drill bit – grabs in work 2. Regrind drill
3. Inadequate chip cleaning 3. Check application setup
Chipping of high-speed drill bit 1. Improper heat treatment after regrinding 1. Follow manufacturers’ recommendations
2. Too coarse feed 2. Reduce feed

14
Fabrication & Machining
MILLING
Periphery milling is used to remove large volumes of plastic
with relatively high accuracy and precision. Mounted in a drill
Consider the following when milling OPTIX sheet:
press, an end mill can remove material with a starting depth » Excessive feed rates can cause chipped edges
of 0.100˝ of the cut per pass and increase depth of cut to » Insufficient feed rates can generate too much heat and cause
1/2 - 2/3 of the cutter diameter. Equip machines with vacuum
part melting
devices or compressed air to clear chips and debris away
from the blades and to control heat generation. » Air or water mist help to cool the part to prevent melted edges

Milling OPTIX® sheet typically works best at feed speeds » Improper milling can induce high stress levels causing
of 5-10 inches/minute and cutting speeds between 100- future problems (ie. crazing or cracking)
200 rpm.
Carbide cutters generally provide smoother finish and allow
for higher feed rates. Special cutters designed specifically
for plastics produce the smoothest finish at the fastest feed
rates. Check with your cutter supplier for the latest designs
for acrylic.

Side View OPTIX sheet

ROUTING
Router cutting produces a smooth edge on OPTIX sheet and Fence
easily cuts curved or irregular shapes. Use a recommended
router speed of 20,000 to 25,000 RPM with a straight 2 or 3
fluted carbide-tipped or high speed bits with diameters 1/4 inch
to 1/2 inch.
Table
A chip load of 0.004˝ – 0.015˝/tooth will create stability better
for the cutter and sheet. Typical feed rate for OPTIX sheet is
from 100 to 300 inches per minute.

General guidelines for router cutting OPTIX sheet: Overhead View OPTIX sheet

Router bit design

Clearance angle 5 - 10°
Feed Direction Fence
Rake angle 0 - 10°
Cutting speed (rpm) 20,000 - 25,000

Router Bit
Table Top

Important: Feed the sheet against the router bit rotation

and use a fence for sizing when making straight,
conventional cuts.

15
 Fabrication & Machining
Machining
Machining equipment used in fabricating OPTIX® sheet are Consider the following when machining acrylic:
varied, such as jointers, edge-finishing machines and shapers. » Chatter marks can be avoided by reducing feed rate speed
Most were originally designed to be used with wood. Use proper
cutting tools in good repair to avoid failure of finished part. » To correct vibration, stabilize platform
Confirm with the manufacturer if the machine can be used to » Work with sharp tools, and avoid using tooling for other
fabricate acrylic. The machine should be balanced to avoid substrates. For example, do not use the same tooling on
vibration and produce clean cuts. acrylic that was previously used on wood.
» To avoid melted edges, increase feed rate
» To reduce chip buildup add compressed air, water, mist of
emulsion cooling

Machining Edges
Many methods are used to produce a desirable edge finish.
Edge finishing machines with diamond cutting wheels, produce
an edge with a polished look, excellent for cementing.

Shapers and table routers can machine square, beveled, Jointers are used to square and prepare edges for cementing
bull nose, ogee, and other decorative edges. or hand finishing. Multiple sheets can be stacked to Increase
efficiency.

16
Fabrication & Machining
Laser Machining
Laser cutting is best achieved when the correct laser wattage is
used. Allow for feed rate to match the thickness of the material,
<0.25˝ at 40 watt and slow feed rate of approximately 20 inches
per minute is best. For thicker sheets or faster feed rate a laser
with a higher wattage is recommended. For most acrylic sheets,
a 180-watt laser is the most economical and provides a clean
edge. Check with the laser manufacturer for recommendations
on laser etching and cutting acrylic. No laser units perform
identically.
Note: different acrylic types require adjustments of laser power
and speed.

Summary on laser machining:

» Increased power of the laser will result in a glossy finish but
this may increase stress in the part
» Laser beams are small bursts not a continuous stream
– Control pulse rate; proportionally to time and distance
» Edge stress is always a possibility
– The highest risk when the sheet is heated and the cut sheet
is vulnerable to crazing
» Adjusting feed and pulse rate and power can minimize stress
» Always cut the sheet to proper blank size before dot laser
etching, otherwise cracking or crazing may occur in the
finished part

TECH TIP: Laser Fabrication – Please check with laser

manufacturer to verify specific laser parameters for etching
or cutting acrylics. In general, when cutting thickness is
comparable on different lasers, using a larger wattage
system will cut the same material at a faster rate.

Laser Raster / Cutting vs Thickness

Cutting
Wattage Vector Up to...
50 Yes Yes 0.25˝ / 6.35mm
100 Yes Yes 0.50˝ / 12.7mm
150 Yes Yes 0.75˝ / 19mm
200 Yes Yes 0.75˝ / 19mm
250 Yes Yes 1.00˝ / 25.4mm
400 Yes Yes 1.00˝ / 25.4mm
Note: these are approximate parameters and will depend on
the application, laser system, and type of acrylic. Be sure to test
before starting production and make adjustments to achieve
desired results.

TECH TIP: Proper safety glasses are recommenced

when using lasers. ANSI Standard Z136.1 states that safety
eyewear must be labeled with the wavelength and optical
density protection factor. Standard safety glasses do not
provide the necessary ratings.

17
 Thermoforming

18
Thermoforming
Thermoforming is a cost-effective and practical processing
method for producing three-dimensional shapes from a flat
thermoplastic sheet using heat and pressure. Thermoformed
parts can be found across transportation, signage, architectural, TECH TIP: OPTIX L – With respect to mold temperatures,
specialty, and industrial markets. Known for its low tooling cost the key is to have the part set. Having a mold temperature
and moderate equipment investment, thermoforming is most of 130°F is sufficient. In cases where you get “cold-flow” you
economical where production volumes are 10,000 parts per may want a specific mold area up and around 170°F. Avoid
year or less. It allows for great design flexibility and serves as a having the mold too hot with temperatures at or above the
practical means for prototyping and pre-production trialing of softening point which could occur around 180°F for OPTIX L.
injection molded applications.

OPTIX® product Vacuum forming Drape forming Line bending

OPTIX Q Q Q

95 / 99 Textured Q Q Q

Duraplex Q Q Q

NB Q Q Q

SG Q Q Q

Thin Q Q –

LD – – Q

UVF Q Q Q

LED Lighting Q Q Q

FABBACK – – –

DA Q Q Q

E-DA – – –

AMGARD Q Q Q

AMGARD SR – – –

L Q Q Q

Black / White Q Q Q

Block Q Q –

Ecoshade Q Q Q

EdgeLit Q Q Q

Frame Q Q Q

Museum Grade Q Q Q

MYST Q Q Q

UTRAN Q Q Q

Q Recommended – Not Recommended

19
 Thermoforming
Forming equipment
When setting up the thermoformer, ensure there is adequate surface and lengthen cycle times. One-sided heating is not
clearance between the clamping frame and mold to allow for recommended for sheet thicker than 0.170˝. Two sided heating
deep sheet sag. Optimize the platen speed and clamp frame to should be used for sheets thicker than 0.170˝. Zone heating
maximize the heating elements. allows different banks of heating coils to be controlled separately
Recommended heater elements include ceramic, quartz, and to produce even heating. Unbalanced heating can lead to a
halogen. Calrods and nichrome elements can also be used, but non-uniform temperature profile in the sheet and is evident by
typically do not perform as well for heating control. The most uneven sag of the sheet.
efficient thermoforming machines have both top and bottom The thermoformer’s reserve vacuum tank must be 4-10x the
heater banks for heating acrylic sheet. One-sided heating limits volume of the largest mold. The pump should be capable of
forming method options, tends to overheat the sheet generating 26-30 inches Hg pressure and shouldn’t drop below
15 inches of Hg during the vacuum cycle.

FORMING TECHNIQUES

VACUUM FORMING PRESSURE FORMING

Selection of a negative tool versus a positive tool depends Pressure forming uses compressed air (up to 100 psi) to force
on the application and is most often determined by the part’s the sheet into the mold. It allows for greater part definition and
appearance or the importance of its fit or assembly. Negative dimensional control. It also achieves more mold surface detail
tooling is used where the ‘outside’ part geometry is more than other methods for applications that require texturing
important than the surface finish. Positive tools are for applica- or lettering.
tions needing ‘inside’ geometry detail and a blemish-free part
surface. Make note that any blemish on the tool (positive or
negative) will result in an imperfection on the part.

Negative Tool Positive Tool

Heating
and sag Pressure Plate
of sheet

Mold
Dropping
sagged
sheet on
mold

Vacuum
applied

Air Pressure
Finished
part

Vacuum

20
Thermoforming
PLUG-ASSISTED FORMING TWIN SHEET FORMING
Plug-assisted forming prevents excessive thinning of material Twin sheet forming uses two sheets of plastic and two negative
in deep-mold cavities. A plug-assisted formed part has more molds in a single clamp frame setup. A blow pin is inserted
uniform thickness in the walls than a part produced by typical, between the sheets, and pumps hot air between them to prevent
single-stage vacuum forming. sticking as they soften and sag. This process requires a two-side
heater bank. Twin sheet forming is ideally suited to hollow parts
with sealed edges, and parts made of two different materials.

Heating Negative mold

upper half

Vacuum

Negative mold
lower half
Air pressure
Plug Assist applied through
needle

Molded halves
sealing sheets
together

Plug Assist

Vacuum
Air pressure
applied through
needle
Vacuum

Sheets formed
against mold interior
with air pressure

Vacuum

Formed
hollow part

21
 Thermoforming
FREE FORMING DRAPE FORMING
Free-blown billow forming (as shown below) is a process used Drape forming requires a felt or flannel covered wood tool, or
for making dome shapes. Apart from the mold, the procedures flocked rubber for making a single radius of curvature parts, or
and equipment are the same as vacuum forming. Billow forming designs of slight contours. Face shields and recreational vehicle
can be done with compressed air or vacuum. windscreens are examples of parts made by this method. The
sheet is typically heated on an oven shelf or other means of
Procedure:
supporting sheet.
1. Preheat clamps and tooling to 130°F for OPTIX, 175°F for
DURAPLEX SG-05, and 170°F for DURAPLEX SG-10 Procedure:
2. Place sheet in clamping frame of thermoformer 1. Pre-drying OPTIX® sheet is not typically required in
3. Heat sheet until uniform sag forms (270-350°F) drape forming

4. Remove heat source 2. High quality, reproducible forming requires consistent

orientation in handling and cutting (top versus bottom), as well
5. Lower pressure box to seal air supply pressure as extrusion direction. Do not flip or rotate sheets.
6. Apply high air pressure initially. As dome takes shape, reduce 3. Heat the sheet to 270°F - 350°F
air pressure
4. Locate the oven shelf at the midpoint of the oven for optimum
7. When overall height is achieved, maintain positive air pressure heat balance. Place a felt covered piece of plywood or other
until part cools flat rigid, heat-resistant sheet on the oven rack or on a portable
8. Be sure air source is properly filtered and uniformly dispersed oven dolly. Be sure to use a fabric cover to protect the sheet
for even formation of dome from scratches.
9. Utilize electric eye designs or micro switches for height 5. Bring OPTIX sheet to forming temperature in the oven at
control and consistency 270°F - 350°F. Depending on gauge, this may take several
10. Remove and trim part minutes. For example, sheet gauges from 0.100˝- 0.375˝
take approximately 1 - 10 minutes.

Blown dome forming Drawn dome forming 6. Manually remove the heated sheet from the oven, and
immediately position it over the felt covered mold.
Heater
Heater Heater
Heater 7. Apply pressure at the edges of the sheet to help the sheet take
the form of the mold or use matched molds (clamshell molds).
Cooling takes about 0.5 - 4 minutes.

Clamp
Clamp Clamp
Clamp Vacuum 8. Always wear thermal gloves when handling hot sheet, holding
Air Air
boxbox Vacuum
frame
frame frame
frame boxbox the material by its edges.

Air Air Vacuum

Vacuum
inlet
inlet lineline
OPTIX
OPTIX OPTIX
OPTIX
Force
acrylic sheet
acrylic sheet acrylic sheet
acrylic sheet

Positive Mold

SagSag SagSag

Electric eyeeye
Electric
sensor
sensor
Electric eyeeye
Electric
sensor
sensor

Negative Mold

Air Air
pressure
pressure Vacuum
Vacuum
applied
applied applied
applied

TECH TIP:
22 Utilize an electronic eye to control height consistency.
Thermoforming
Molds Vacuum forming heating cycle
Extremely durable and higher quality than lower cost counter- The target sheet temperature for vacuum forming OPTIX® is
parts, aluminum molds are ideal for high volume and recurring between 270°F to 350°F for 0.100˝- 0.375˝ thick sheet. The
production programs. However, for limited or small run volumes, temperature profile of the sheet will define the resulting sag
less expensive mold materials like epoxy, fiberglass and wood in the sheet. Maintaining the sag depth and shape provides a
may be more economical choices. visual indicator for forming consistency.
Note: Aluminum tools require internal heating to maintain a
surface temperature of 130°F for OPTIX®, 175°F for DURAPLEX
SG-05, and 170˝F for DURAPLEX SG-10. TECH TIP:
Heating from top and bottom shortens cycle time.
Mold design
Mold shrinkage: Molds require oversizing in their design to
compensate for part shrinkage due to cooling. The typical mold
shrinkage value for OPTIX acrylic is 0.2% - 0.6%, or 0.002 in/in Characteristics of thermoforming acrylic
to 0.006 in/in.
While OPTIX sheet forming characteristics are different than
The typical mold shrinkage value for Impact-modified acrylic is other thermoplastic sheet materials, it outperforms them in
0.3% - 0.7%, or 0.003 in/in to 0.007 in/in. production efficiency due to its short heating times, and rapid
forming and cooling cycles.

Important reminders for thermoforming OPTIX

3.021˝ » Thermoforming temperature is relatively narrow: 270°F - 350°F
Mold
» Acrylic has a softening temperature of 210°F - 220°F
» Normally OPTIX does not need to be pre-dried unless forming
temperatures are excessive (or the sheet has absorbed
3.00˝ significant moisture)
Part
» Acrylic cools rapidly. Platen movement and clamp
Draft Angles: Draft angles greater than 5° allow for easier frame travel must operate at appropriate rates without delay
removal of the part from the mold.
» Pre-drying is, however, recommended before forming sheet
Radii and Fillets: Use generous radii wherever possible. The that was vinyl laminated (wet lamination)
radius minimum should be equal to or greater than the starting
material thickness, as this minimizes the thinning of the sheet,
improves part rigidity and avoids creating a stress riser point. Forming temperatures
On negative tooling, use corner fillets.
Sheet temperature
Vacuum Holes: To form sheet rapidly and allow for fast air
Typical 270°F - 350°F
evacuation make several holes with small diameters. A 0.030
inch diameter hole is usually small enough unless the part’s Optimum
wall thickness is less than 0.030˝. In negative molds, use air OPTIX 320°F
evacuation holes at all deep draw areas, especially around the Duraplex SG-05 315°F
mold perimeter where the sheet draws last. Duraplex SG-10 310°F
Mold temperature
Tips on mold design OPTIX 130°F
» In both positive and negative tooling, keep the diameter of the Duraplex SG-05 175°F
drilled holes no larger than the thinnest wall section to avoid Duraplex SG-10 170°F
marking the sheet. Additionally, in negative tooling, design long
thin slots for air evacuation.
» Vapor hone or sand blast metal tools for a uniform
surface finish
» A highly-polished mold surface is not recommended as it
causes sticking and air pockets
» The radius minimum should be equal to the sheet’s original
thickness to relieve stress riser points
» Preheat mold. Cold molds can cause surface defects, warping,
and may increase internal stress in the part
» If mold temperature becomes too high during thermoforming,
OPTIX sheet can stick to the mold. Control mold temperature
to 130°F for OPTIX, 175°F for DURAPLEX SG-05, and 170˝F for
DURAPLEX SG-10. 23
 Bending,
Annealing

24
Bending
Cold Bending
A bend in OPTIX® acrylic sheet can be accomplished without
applying heat. A minimum radius of 200 times the thickness of
the acrylic is required to avoid stress cracking.

Line bending or strip heating Strip heating device

Line bending, also referred to as strip heating, is a technique
for producing linear bends. For thicker sheets, back routing or
V-grooving along the bend line is recommended.
There are several options for line bending OPTIX acrylic sheet.
The most commonly used method for a straight bend is to use Nichrome
a straight nichrome wire resistance heater for sheet thickness resistance wire
up to 0.118˝. Thickness greater than 0.118˝ may be bent but (or Calrod type
V-grooving
the material must be flipped over halfway during the heating heater)
radius (1/16˝)
cycle. Heat the material until it softens. Place the bent part into
a cooling jib. Secure with weights or clamps. Cool roughly the
same amount of time it took to heat the sheet. Do not overheat
or lay the OPTIX sheet on the elements or the sheet may blister Milled groove to accept Nichrome
or retain marks. wire (approximately 1/16 - 1/8˝ below Back routing
surface of OPTIX sheet). Do not radius (1/16˝)
*Please be aware an unguarded nichrome wire is a shock/
allow wire to contact sheet directly.
burn hazard. Proper guard and PPE are encouraged
Coiled resistance wire can be used in place of the straight
wire element. It is more difficult to evenly heat a coiled wire
across the sheet surface which could cause uneven stress and
distortion. Follow the same method as used with the nichrome
wire resistance heater. However, flip the sheet over to obtain Tubular Rod Heaters
even softening of the sheet prior to bending.
Tubular rod heaters are used to heat OPTIX sheets thicker than
Procedure: 0.118˝. When using rod heaters an aluminum reflector is needed
1. Remove protective masking in bend area to deflect the heat into the sheet. Heaters can be placed above
and below the sheet and use water-cooled supports to avoid
2. Regulate heating element to 270°F - 350°F mark off on the OPTIX sheets. Follow the same method as used
3. Place sheet over heating element at bend area with the nichrome wire resistance heater; however, the acrylic
4. Allow heat to soften material. The amount of time sheet should be at least one half inch away from the heaters to
depends on gauge avoid overheating.

5. Remove sheet and make desired bend on a felt

covered fixture
6. Bend immediately as acrylic cools quickly
7. Allow part to cool on the fixture until set up - OPTIX
about 30 seconds sheet
Note: Some bends may require a degree of over-bend
to achieve desired angle.

TECH TIPS:
» Line bending works best for lengths of 24˝ or shorter.
Longer dimensions require preheating the entire piece to
200°F first to prevent warping.
» Even heating, perpendicular to the sheet’s manufacturing
direction is recommended (to avoid post bending shrinkage
in the extrusion direction).
» For best results with gauges greater than 0.177˝, use
two-side heating, or turn the part frequently when using a
one-side heater. This helps with even heat penetration,
preventing moisture bubbling.
» Additionally, for gauges greater than 0.177˝, back route or
V-groove with a 1/16-inch radius to heat cross section.
Again, this will help avoid moisture bubbling, while still
creating a sharp angle. 25
 Bending
“V” groove
Radiant Quartz Tube Heaters
Radiant quartz tube heaters are an efficient means of energy.
These heaters have the capability to bend OPTIX® acrylic sheet
0.060˝ and greater. To achieve the most efficient heating use an OPTIX sheet
aluminum reflector with a quartz tube heater. Follow the same
method as used with the nichrome wire resistance heater. To
avoid overheating the sheet maintain a distance of at least one
half inch from the heaters.
To achieve the best line bends be sure to use a 90° cooling jig
to maintain the proper angle of the sheet bend. This will prevent
the sheet from returning to its original shape and reduce stress
on the part as it cools. This jig can be modified to each part.
To create a bend less than 90° increase or decrease the heated
area. With this method, the sheet can be bent to a more
gentle curve.

TECH TIPS:
» Do not use hot air guns to heat OPTIX sheet for bending.
A heat gun produces uneven heat which could cause warp.
» To minimize bowing when making long line bends of 24˝ 90° Cooling Jig
reduce the width of the heated sheet or V-groove the sheet
along the bend line. When it exceeds 36˝ the bend should
run perpendicular to the direction of extrusion (DOE); if
this is a requirement please consult customer service when
placing your order.

Troubleshooting for bending

Description of problem Probable cause Remedy
Bubbling or blistering Overheating Increase sheet and heater distance
Lower heat
Reverse or flip sheet
Wet Material Pre-dry sheet
Wrinkling Bending part the wrong way Bend away from heated side
Narrow heating Increase bend radius, should be at least
twice sheet thickness
Widen heated area
Mark-off Sheet surface contact Avoid overheating
Cover cooling jig with felt and reduce
contact with jig
Bowing Stress on heated and unheated areas Use nichrome wire to decrease heated area
Reverse curve in cooling jig
Heat part in oven
Use v-groove to bend line
Shrinkage in sheet Bend sheet perpendicular to DOE –
contact manufacture for details

26
Annealing
The roughness and solvent-craze resistance of internally
stressed acrylic sheet can sometimes be improved by relieving
the stress through annealing which increases the strength of
cemented joints. Acrylic sheets can be annealed by heating
them in a forced-air oven below the temperature which will
cause the part to distort. Time required for annealing depends
on the annealing temperature, the thickness, and the type of
acrylic involved. In general, a longer time at lower temperatures
is preferred to shorter times at higher temperatures.
Annealing temperatures will normally be in the range of 140° to
180°F (60° to 82°C), with annealing times in the range of 5 to 8
hours. After heating for the suggested time, the parts should be
cooled slowly to at least 110°F (43°C).
To obtain maximum benefit from annealing, the parts should be:
1. Annealed after all fabrication has been completed
2. Free of protective spray coatings or masking paper
3. Annealed in a uniformly heated, forced-air oven rather than
by immersion in hot liquid
4. Cooled slowly to room temperature after annealing
(For example, some fabricators cycle their oven temperatures
so the annealed parts will cool slowly overnight in the oven.)

Suggested Annealing* Times

Acrylic Sheet Thickness Annealing Time
(inches) (mm) (hours)
0.125 3.2 2

0.250 6.4 4

0.500 12.7 6

1.000 25.4 8

*These values reference OPTIX L products.

27
 Bonding

28
Bonding
Cementing Dip or Soak cementing
Successfully cementing OPTIX® acrylic sheet begins with a Place small wire brads in a dip or soak tray. Cover the brads
well machined part. A square flush fit is required to produce a with a moderate amount of solvent. Rest the edge of the OPTIX
strong, clean joint and will minimize the chance of “blushing”. acrylic sheet on the brads for 1-5 minutes depending on the
thickness of the sheet. Remove the sheet from the solvent to
For best results preparation of the areas to be bonded are
drain off the excess liquid. Quickly and precisely place the edge
critical. Edges must be cleanly cut and properly machined.
on the other part, being careful not to apply pressure. After
Finish rough edges or wet-sand the edges with a flat surface or
initial bonding (30 seconds) apply slight but steady pressure
block. Do not polish edges prior to cementing.
to remove air bubbles but take care not to squeeze out the
Types of cement used for bonding acrylic are: cement. Allow the joint to cure by placing in a jig for 5-20
minutes before moving the part and wait 8-24 hours before
Solvent cements – water thin solvents to soften the acrylic, any additional machining or finishing. The bond will continue to
which will diffuse and evaporate allowing the parts to strengthen over the next several weeks.
harden together
Mixed solvent cements – Thickened with an acrylic polymer to
slow cure times and fill small voids
Polymerizable cements – Methyl methacrylate monomer and
a catalyst mixed to produce a cement for strong, long lasting
museum quality joints

Capillary cementing
This technique allows solvent cement to flow into the joint and
melt the parts together. Apply cement with a syringe, solvent
applicator or an eyedropper. Use small weights, fixtures and
fences to hold the parts in place. Initial bonding occurs within Capillary action
5-10 seconds. A three-hour cure time is sufficient to allow draws adhesive
further fabrication and a 24-48 hour for maximum into joint
bond strength.

TECH TIPS:
» Cement should be used in a well-ventilated area
» Low humidity will prevent cloudy joints
» Parts to be bonded should not be flame or buff polished
» Protect skin from cements and solvents
» Ideal temperature 70°F -75°F
Troubleshooting
Description of problem Probable cause Remedy
Bubbles in joint Uneven surface Prepare joints for squareness
Use solvent cement
Crazing Stress in material Use proper ventilation when bonding
Anneal heat bent areas
Dry before flame polishing
Use water when sanding to reduce temperature
Joints whitening Water in cement Replace cement
Fast evaporation Reduce evaporation rate by adding glacial acetic
acid 1-3% strength
Weak joints Uneven surfaces Check joint for squareness
Issue with cement Use solvent cement
Store cement properly – follow manufacturers
instructions (Solvent evaporation can change
cement characteristics)

29
 Mechanical
Fastening

30
Mechanical Fastening
Mechanical fasteners Fastening with self-tapping screws
OPTIX® acrylic sheet may be attached with screws, nuts and Thread-cutting screws may not be appropriate in all applica-
bolts, rivets, or other mechanical fasteners. However due to tions and environments. Cracks around the screw hole may form
fluctuating temperatures allow for expansion and contraction under conditions where the acrylic expands and contracts due
of the substrate. Drilling oversized holes or slots, using washers to temperature variations. Use thread-cutting screws, which cut
and spacers, and not over tightening the fasters will allow the away material from a pre-drilled hole to form a mating thread
OPTIX sheet to move as needed. and result in better long-term performance. Note the radial and
hoop stresses imparted to the part by thread-cutting screws
are lower after installation vs. thread-forming screws. Typically,
Common head styles of screws and bolts thread-cutting screws are classified as ANSI BT (Type 25),
ANSI T (Type 23).
Pay special attention to the fastener’s head. Use bolt and
screw heads that have a flat underside, called “pan” or “round”
head. This bolt design imparts lower compressive stresses on
the material. Conical heads, called flat or oval heads, produce
undesirable tensile and hoop stresses and should be avoided.

Washer
Flat Type 23 Type 25 Hi-Lo™
Filister Thread-Cutting Thread-Cutting Thread-Cutting
Screw Screw Screw
Hex and
Square
Hi-Lo is a trademark of ITW Shakeproof
Truss
Oval
Pan Fastening with rivets
Rivets offer a low-cost and simple hardware solution for static
parts. Aluminum rivets are preferred over harder materials. Select
rivets with large flat heads and three times the shank diameter.
Use of washers on the flared end are helpful in distributing loads,
Fastening with bolts, nuts, and washers but be careful not to over-tighten as it can result in compressive
stress and damage to the plastic.
Use Washers Four standard rivet heads

Use Correct
Correct Incorrect
Incorrect
Standoffs

Correct Correct
Button
Button Truss
Truss Flat
Flat Pan
Pan Countersunk
Countersunk

Use flat aluminum or hard plastic washers under nuts and

fastener heads to evenly distribute the applied force. Their ability
to resist over-compression helps to prevent localized stressing
of the joining part. Ensure there is sufficient distance between
the edge of the fastener’s hole and the part’s edge: at minimum,
two-times the diameter, and twice the part’s thickness. Note:
Incorrect Incorrect Slotted holes require more edge clearance.

TECH TIP:
Avoid thread locker products and countersunk screws. They
are generally incompatible with OPTIX acrylic sheet, causing
cracking and crazing.

31
 Mechanical Fastening
Joining dissimilar materials
For assemblies constructed of a combination of OPTIX® sheet
and metal (two dissimilar materials), it is important to design
for thermal effects. When heated, the plastic may buckle, due to
its higher thermal expansion rate. Conversely, when cooled, the
greater thermal shrinkage of plastic will cause strain-induced No allowance for
stress and may exceed the plastic’s working limit. This could lead expansion
to part failure.
The figure to the right shows a plastic part fastened to a metal
component. As the ambient temperature rises, the plastic will
expand more than the metal because the plastic’s coefficient of
linear thermal expansion is four times higher.
For applications where wide temperature variations exist, use
slotted screw holes in the plastic part. When joining plastic and
metal parts, do not tighten fasteners to the point where joint
friction and compressive loads prevent relative movement. If the
fasteners are too tight it negates the effect of the slotted holes.
Slotted hole allows
Factors to consider when joining plastic and metal parts: for expansion
» The size of the parts to be joined
» The magnitude of the temperature range
» The relative thermal expansion coefficients of the materials
used in the part

Restricted assembly design, not recommended Allow for relative movement in assemblies
of dissimilar materials
CORRECT INCORRECT
OPTIX Part Metal Part
OPTIX Panel

Metal
Bracket Slotted
Hole The slotted hole could be in
Soft either piece, as long as
Washer relative movement is allowed.
Fastener
Slotted Holes Metal Bracket

There are many “J” clips

and fasteners that will allow
relative movement in assemblies.

32
Mechanical Fastening
Coefficient of Linear Thermal Expansion (CLTE) values for materials

Material CLTE (10-5 in/in/°F)

OPTIX® 3.0 A simple calculation is to allow 1/16˝ per linear foot for
Aluminum 1.3 expansion and contraction

Example 1: Calculate the change in length for a 96 inch part that is constructed at 70° F,
but will see operating temperatures up to 120° F
∆L = (plastic CLTE) * temperature change * length of part = (0.000030)*50*96 . . . . . ∆L = 0.144 inches
Therefore, the design has to accommodate a growth of 0.144 inches.

Example 2: How much shrinkage will the same part see at -20° F
∆L = (plastic CLTE) * temperature change * length of part = (0.000030)*90*96 . . . . . ∆L = 0.26 inches
Therefore, the design has to accommodate a contraction of 0.26 inches.

Ultrasonic welding For optimum welding:

Sonic welding can be used to press parts together. The use of » The horn, fixture and parts must be aligned properly
electrical energy is converted to mechanical vibration, melting
» The stationary part should fit snugly in the nest or fixture
the acrylic sheet to create the bond.
» The height of the energy director should be approximately
An ultrasonic welder has two primary parts: a horn and a nest.
0.020 inch
The horn typically presses down on the upper plastic part (of
the two to be welded), clamping the two parts together. The » Join parts made of the same resin
nest supports the bottom plastic part to prevent it from moving.
The horn is vibrated ultrasonically for a preset time. Friction
from mechanical vibrations cause localized heating, resulting
in plastic melting at the interface of the two parts. Pressure
is then maintained after the vibrations are stopped until the
melted plastic cools. Once the plastic has solidified, the clamping
1/4 W
pressure is retracted and the two joined parts can be removed
from the nest fixture.
The most important feature for a clean, ultrasonically welded
joint is for one of the parts (to be welded) be designed with
a triangular-shaped energy director. This minimizes the initial
contact between parts. During welding, the ultrasonic energy is
concentrated at the director tip, melting it and ultimately, joining
the interface with molten resin.
60 - 90°
Design energy directors with an apex angle from 60 to 90°.
Generally, the base width of the energy director should not be
more than 20 to 25% of the wall thickness supporting it.
W

33
 Painting,
Finishing

34
Painting
OPTIX® acrylic sheet can be easily decorated using commer- The use of backlighting during the process will aid in
cially available paints produced specifically for acrylic or determining the uniformity of the paint application. Certain
vinyl. Be sure to use only paints that have been tested to be restrictions, such as heating temperature, time and depth of
compatible with OPTIX sheets. Follow paint manufacturers draw, and the thickness of the paint will affect the quality of the
guidelines for thinners, viscosity, methods, and volumes for end product. Refer to the manufacturers guidelines for details.
optimal results. Proper machining, forming and fabricating
techniques should be followed to reduce the chance of crazing. Paint removal
After handling and fabrication, clean the OPTIX sheet. Remove
Remove excess paint immediately from the acrylic sheet using
dust, masking residue and static charges prior to painting or
approved cleaners. Using a clean, soft rag, wipe the paint off
vinyl application. Painting reduces the impact resistance of
to reduce the chance of crazing. Be sure to minimize the time
OPTIX and design considerations should be taken into account
cleaners are in contact with OPTIX acrylic sheet.
to minimize potential damage.
OPTIX acrylic sheet is excellent for back painting, which is Vinyl decorating
applying paint to the side that will be not exposed to weather
Application of colored vinyl film is a common decoration
elements. However, if you need to expose the painted surface
technique for OPTIX acrylic sheet. Follow the vinyl film
apply a protective coating over the paint. Suppliers can
manufacturer’s directions for product use.
recommend a suitable coating.
The use of masking in a paint operation will provide a protective Digital printing
layer for flat signs. A liquid maskant may be used when applied
10-12 mils thick wet (3-5 mils dry) for spray paint designs. These UV cured inks are used in digital printing due to their quick
maskants are water solutions and must be stored above 32°F cure times. Historically a UV mercury arc lamp has been used
to prevent freezing. Minimum drying time is 2 hours but it is as the light source but newer UV LED curing lamps are now
better to allow the maskant to dry overnight to assure complete preferred. These bulbs use less electricity, produce less heat,
evaporation. Prior to painting score the design on to the film last longer and do not require a warm-up period. It’s important
with enough pressure to cut the film without scratching the to note the market has reported intermittent adhesion issues
OPTIX sheet. Leave the film in place until the paint has when printing on plastic substrates when curing with UV LED
dried completely. systems. Pretreating the plastic substrate with corona discharge,
flame, UV light, solvent wipes or adhesion promoters has proved
Best results for spray painting is achieved with an atomizing
successful in overcoming adhesion issues.
spray gun to uniformly distribute paint free of water and oil.

Troubleshooting
Description of problem Probable cause Remedy
Maskants
Weak and brittle maskant Air bubbles in film Dilute slightly
Film not thoroughly dry Wait recommended drying time
Excessive adhesion Maskant film too thin Increase film thickness to 3-5 mils (10-12 mils)
Coating exposed to UV Do no store sprayed acrylic outdoors

Spray Painting
Poor adhesion Incorrect paint Use paints recommended for use with acrylic sheet
Dirt or residue on sheet Clean surface before painting
Blotches of paint Static electricity Neutralize charges with ionizing wands, bars or air
blowers. Wipe sheet with a soft rag and a mixture
of water/IPA (30%). Avoid using commercial
cleaners or anti-static solution as they may affect
ink adhesion and print quality

Screen Printing
Poor Detail Screen mesh too coarse Use a finer mesh
Paint too thin Reduce thinner additive
Worn screen Replace screen
Paint drying on screen Hot, dry weather Add retardant to slow paint drying
Large lapse of time between screening Flood screen between passes

Crazing Stress from fabrication Review fabrication methods

Flame polishing Flame polish as last step
35
 Finishing
Scribing & Breaking Flame Polishing
For OPTIX® acrylic sheet up to 1/4˝ thick, score repeatedly along A hydrogen-oxygen torch, with a #4 or #5 tip, gently melts the
a straight edge with a plastic cutting tool, or Fletcher Terry sanded or machined edges of OPTIX acrylic sheet, providing
Knife. Score to penetrate 1/2 through the sheet. Align the score a smooth glossy look. Low line pressures create a torch flame
with the edge of the table and apply gentle pressure to break that is 2-3˝ long, bluish, nearly invisible, and narrow enough to
the sheet along the score line. prevent overshooting onto the face of the acrylic sheet.
Remove the masking from the acrylic sheet and guide the torch
along the edge at a rate of approximately 3-4˝ per second. As
with other cutting and machining processes, avoid excessive
heat build up. Bubbles, stress, and crazlng wlll occur if the flame
is moved too slowly. Do not cement a flame-polished edge.
As a reminder, flame polished parts can be annealed to reduce
internal stress.

Scraping
Scrapers are sharp tool-steel devices used to eliminate
machining marks and ease sharp edges.

Buffing
A well machined edge is required to polish without additional
sanding. Preferably, use stationary machines with polishing
wheels dedicated to buffing acrylic. Wheels 8-14” diameter, 2-3˝
Sanding wide, of bleached muslin with bias strips, run cooler than ones
All methods of sanding will result in the removal of machining fully stitched. With light pressure, keep the OPTIX acrylic sheet
marks, and produce a matte finish. The choice of hand, palm, moving across the wheel to prevent excess heat build up.
random orbit, disc, belt, or drum sanding, depends on the Finish quality depends on the polishing compounds used.
quantity, size and shape of the acrylic sheet. Like sanding wood, A medium cutting compound will result In a good finish in one
work from coarse to fine paper. Use light pressure, and keep the operation. A high luster finish can be achieved by first applying
part or sander moving to avoid heat build up. After sanding, the a fast cutting compound, to remove machining and sanding
edge is ready for buffing or flame polishing. It should be noted marks, followed by a fine compound on a finishing wheel.
that mechanical sanding, even aggressive hand sanding can
induce heat stress in the sheet. This could increase the risk of
crazing if not managed properly.

36
Finishing
Troubleshooting
Problem Probable cause Remedy
Dull edge after flame polishing Missed spots Allow sheet to cool and reflame
Too much heat If necessary change torch tip size
Char on edge Wrong fuel type Use oxygen/hydrogen mixture
Dirt or contamination Wipe with lint free, dry cloth prior to flame polishing
Too much heat Reduce heat in 2° to 5° increments until desired
edge is obtained
Edge blister Wet sheet Pre-dry sheet
Crazing after flame polishing Incompatible cleaner used prior Use approved cleaners
or at conclusion of flame polishing

Handling and Maintenance

Proper storage of OPTIX® acrylic sheet is important to protect
the material from dirt and moisture. Leave the protective wrap
on the pallet until ready to use to minimize warpage. Sheets
should be stored vertically where they can at approximately 10%
angle. The racks should be constructed of full sheets of plywood
to support the weight of the material.
OPTIX acrylic is protected with film masking from scratches.
Film masking can be marked with grease pencils or certain felt
tip markers and for paper masking pencils, pens and felt tip
pens can be used to write on the masking.
Sheet masking should be left on during the fabrication process
to protect the sheet surface. It may be removed if necessary but
care must be taken to not damage the sheet. Avoid handling
unmasked sheet unless necessary.
Masked OPTIX sheet should be stored away from sunlight, heat
and humidity, and the masking should be removed upon instal-
lation. If masking is left on the sheet after installation, it may
become difficult to remove.

37
 Troubleshooting
Guide

38
Troubleshooting Guide
Description of Problem Possible Causes Possible Corrective Action

SAWING
Chipping on edge of sheet • Feed rate is too fast • Slow the feed rate

• Teeth on blade bent • Check condition of blade so teeth

are correctly positioned

• Vibration of stacked sheets

• Clamp sheets together tightly

Melting of acrylic • Dull blade • Sharpen blade

• Feed rate is too slow • Increase feed speed

• Incorrect blade angle • Blade angle should be parallel to

direction of travel

• Stopping of sheet while sawing • Material needs to move evenly

through saw

CEMENTING
Crazing in machined edge of
cemented joint • Stress due to machining • Make sure the tool is sharp
• Check speed of tool
• Anneal parts before cementing
to reduce pressure

• Edge polishing • Do not polish prior to cementing

• Chemical attack by cement • Change type of cement

Cloudy joints • Excessive moisture • Use slower evaporating solvent

• Reduce environment humidity

Poor joint strength • Bubbles • Improve surface contact between parts

• Dry spots • Use slower evaporation solvent

• Extra solvent squeezing from joint • Reduce clamping pressure

• Solvent action reduced because of low • Warm solvent

ambient temperature • Increase room temperature

39
 Troubleshooting Guide
Description of Problem Possible Causes Possible Corrective Action

SPRAY PAINTING
Poor adhesion • Incorrect paint • Use paints recommended for use
with acrylic sheet

• Dirt or residue on sheet • Clean surface before painting

Blotches of paint • Static electricity • Neutralize charges with ionizing gun

• Wipe with damp cloth

SCREEN PRINTING
Poor Detail • Screen mesh too coarse • Use a finer mesh

• Worn screen • Replace screen

• Paint too thin • Reduce thinner additive

Paint drying on screen • Hot, dry weather • Add retardant to slow paint drying

• Large lapse of time between screening • Flood screen between passes

Crazing • Stress from fabrication • Review fabrication methods

• Flame polishing • Flame polish as last step

THERMOFORMING
Bubbles • Overheating • Lower temperature
• Shorten the heating cycle
• Increase the distance between heat
and sheet

• Moisture • Pre-dry material before forming

• Keep masking on sheet until formed
• Attach baffles, circulate heated air

Bumps in formed part • Entrapped air between sheet and form • Change venting system

• Mold temperature too cold • Increase mold temperature or

preheat mold

• Sheet too hot leaving mark-off from • Lower temperature

the mold • Shorten the heating cycle

Crazing in formed skylights and • Plasticizer in gasket on finished part • Change material in gasket
other glazing applications • Flexible vinyl gasket not recommended
• Chemical put on formed part to clean • Use mild soap and water, isopropyl
or polish alcohol or recommended cleaner

• Stress concentration • Round or bevel the mold corners to a

45° angle

40
Suggested
Vendors

41
 Suggested Vendors
SAW BLADES ROUTER BITS DRILL BITS BUFFING SUPPLIES
Dino Saw Company Amana Tool Corp. Craftics, Inc. Osborn
518.828.9942 800.445.0077 505.338.0005 800.438.6880
340 Power Ave. 120 Carolyn Blvd. 2804 Richmond Dr. osborn.com
Hudson, NY 12534 Farmlngdale, NY 11735 Albuquerque, NM 87107
dinosaw.com amanatool.com craftics.net
INKS & PAINTS
Forrest Mfg. Co. Inc. Boshco, Inc. FTM, Inc. Akzo Nobel Coatings Inc.
800.733.7111 978.667.1911 530.626.1986 800.618.1010
457 River Road 6K Dunham Road 327 Industrial Drive akzonobel.com
Clifton, NJ 07014 Billerica, MA 01862 Placerville, CA 95667
forrestblades.com boshco-dustek.com fabricationtoolsandmaterials.com Nazdar
913.422.1888
FS Tool Corp. Dino Saw Company Onsrud 8501 Hedge Lane Terrace
800.387.9723 518.828.9942 800.234.1560 Shawnee, KS 66227-3290
P.O. Box 510 340 Power Ave. 1081 S. Northpoint Blvd. nazdar.com
210S. 8th St. Hudson, NY 12534 Waukegan, IL 60085
Lewiston, NY 14092-0510 dinosaw.com onsrud.com PPG (Spraylat)
fstoolcorp.com 800.441.9695
Onsrud ppg.com
CEMENTS
FTM, Inc. 800.234.1560
530.626.1986 1081 S. Northpoint Blvd. IPS Corp.
327 Industrial Drive Waukegan, IL 60085 800.421.2677
Placerville, CA 95667 onsrud.com 455 West Victoria Street
fabricationtoolsandmaterials.com Compton, CA
Saber Diamond Tools Inc. ipscorp.com
KANEFUSA Corp. 770.456.0101 or
859.283.1450 888.240.4324 Parker Lord
621 Dolwick 1010 Saber Parkway 877 ASK LORD (877.275.5673)
Erlanger, KY 41018 Villa Rica, GA 30180 lord.com
kanefusa.net saberdiamond.com

Selected product web links:

Ultrasonic joining techniques:

Dukane Corp. http://www.dukane.com/
Forward Technology Industries, Inc. http://www.forwardtech.com/
Herrmann Ultrasonics, Inc. http://www.herrmannultrasonics.com/
Ultra Sonic Seal Co. http://www.ultrasonicseal.com/

Solvent / chemical suppliers:

Epoxy: http://www.masterbond.com/lp/performance-properties-and-common-applications
Silicone: http://www.tremcosealants.com/products/proglaze-ssg.aspx
Adhesive Tape: http://solutions.3m.com/wps/portal/3M/en_US/Adhesives/Tapes/Brands/3M-VHB-Tape/
Hot Melt: https://www.bostik.com/us/Bostik-products/thermogrip-h2315-02-hot-melt-pressure-sensitive-adhesive

42
NOTES

43
A GLOBAL LEADER IN THE PRODUCTION OF THERMOPLASTIC SHEET
FOUNDED IN 1950
Our Mission: to deliver superior thermoplastic sheet, coatings and polymers to the world, through
long-lasting customer relationships and hands-on customer service.

MANUFACTURING LOCATIONS

From our founding, PLASKOLITE strives QUICK FACTS

to treat our employees, our customers,
our community and the world, with STATUS: Privately held
kindness, dignity and respect. This drives
our continuing effort to create sustainable GLOBAL HEADQUARTERS: Columbus, OH
products, in a sustainable manner,
for future generations. This on-going EMPLOYEES: 1800 Worldwide
commitment is expressed in the
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PLASKOLITE Sustainable Ecosystem: Display, Construction, Transportation, Security,
Bat & Spa, Industrial, Architecture, Green Houses

OUR PILLARS OF SUSTAINABILITY

EACH CONTRIBUTES TO MAKING THE WORLD A BETTER PLACE

WHAT WE MAKE Versatile, high-quality, durable

thermoplastic materials...not single-use
plastics

HOW IT’S MADE How we make our products reflects

our overall philosophy of continuous
environmental improvement

HOW IT’S USED Our thermoplastics play an important

role in advancing human well-being,
energy conservation and quality of life

These suggestions and data are based on information we believe to

be reliable. They are offered in good faith, but without guarantee, as
conditions and methods of use are beyond our control. We recommend
that the prospective user determines the suitability of our materials and
suggestions before adopting them on a commercial scale.

© 2022 PLASKOLITE, LLC 082022 BRO066

OPTIX® is a registered trademark of PLASKOLITE LLC