Short answer: Most acrylic electronics enclosures use 1/8 in. sheet with tab-and-slot joints, so they snap or screw together without glue. Add holes for M2.5 or M3 standoffs to hold the board, vent slots over hot chips, and cutouts for every port with about 0.5 to 1 mm (0.02 to 0.04 in.) of clearance.

Why acrylic works for electronics

Acrylic is an electrical insulator, it's easy to cut with tight tolerances, and clear sheet lets you see status LEDs without drilling light pipes. A laser-cut case for a small board like a Raspberry Pi or Arduino is a stack or box of flat parts, so changes cost nothing but a redrawn file. It's a good material for desk projects, home automation hubs, test fixtures, and classroom kits.

Acrylic doesn't shield radio interference and it won't take much heat: keep it under about 160 °F (71 °C) continuous. That's fine for most boards, but give voltage regulators and power transistors airflow, and don't let a hot heatsink touch the panel.

Three ways to build the case

Layered sandwich

Two plates (top and bottom) with the board on standoffs between them. Simplest to design, open on the sides so every port is reachable. Good for development boards you keep plugging into.

Tab-and-slot box

Six panels with interlocking fingers, held with small screws and captive nuts in T-slots, or a drop of cement. This is the most common enclosed case. Our tab-and-slot design guide covers finger widths and the T-slot trick.

Bonded box

Solvent-welded seams for a clean, glue-line-free look, usually with a removable screwed-on lid. Best for finished products and displays. We build these through acrylic fabrication.

What thickness and color to choose

  • 1/8 in. is the standard for small enclosures. It's stiff enough for boxes up to about 6 in. on a side, and tab-and-slot joints stay compact.
  • 3/16 in. for larger boxes, or when you want screws threaded into the panel edge.
  • 1/4 in. for base plates that carry weight, and for tapped holes.

Clear cast shows the board. Black hides the wiring and makes LEDs pop through small holes. Frosted or white translucent diffuses status lights into a soft glow. Gray and bronze tint look sleek and still show the board in a lit room.

Design tips

  • Standoff holes: M2.5 standoffs need about a 2.7 mm (0.106 in.) hole; M3 needs about 3.2 mm (0.126 in.). Check the board's datasheet for hole positions, not a photo.
  • Port cutouts: add 0.5 to 1 mm (0.02 to 0.04 in.) all round. Connector housings vary, and a plug with a fat overmold needs more.
  • Slot fit: laser kerf removes about 0.006 to 0.010 in., and sheet thickness varies, so measure your sheet or let us adjust. See press-fit tolerances for acrylic.
  • Vents: rows of 0.08 to 0.12 in. slots above the processor and on the opposite side low down let air flow through by convection. Hexagon patterns look good and stay strong.
  • Labels: engrave port names, a logo, or a serial number. Engraved text on clear sheet reads best over a dark board.
  • Cable relief: a notch with rounded corners lets a ribbon or USB cable exit without a full slot.

Tip: before ordering a run of cases, order one and test-fit the board, the plugs, and the screws. A 0.02 in. mistake on a USB-C cutout is cheap to fix on the second batch and annoying on the hundredth.

How to order

Send your DXF or SVG with every panel, the holes, and the engraving on separate layers, and we'll check it before cutting. Use upload a drawing for a full case, or the instant quote for simple plates. Quantity pricing applies automatically, which helps for kits and small product runs.

Questions

Is acrylic safe to put around electronics?

Yes. Acrylic is a good electrical insulator. Just keep it away from parts that run hotter than about 160 °F (71 °C), and leave vents for airflow.

Does acrylic cause static problems for boards?

Acrylic can build up static when rubbed, mostly while you peel the protective film. Peel it away from the board and ground yourself as you would for any electronics work; once assembled it's rarely an issue.

Can I screw directly into the acrylic?

Into 1/4 in. or thicker sheet, yes, with tapped holes and light torque. For 1/8 in. sheet, use through-bolts with nuts, or captive nuts in T-slots.