Short answer: Make router templates from 1/4 to 1/2 in. clear acrylic: 1/4 in. for small templates and handheld trim routers, 3/8 or 1/2 in. when a bearing needs more edge to ride on or the template is large. Clear lets you line the template up with layout marks, and laser or routed edges are accurate enough to copy straight to the workpiece.
Why acrylic for templates
MDF and plywood work fine for templates, but they hide what's underneath. A clear acrylic template lets you see your centerlines, knots, and the grain you want to feature, so you can place the cut exactly. It also holds its shape: acrylic doesn't swell with humidity, the edges don't fuzz or dent as fast as MDF, and a cast acrylic edge stays smooth for a bearing to ride on through many passes.
Typical uses include inlay and bowtie templates, hinge and lock mortise jigs, sign letter templates, cabinet handle cutouts, guitar body and neck pocket templates, radius corner jigs, and circle or arc templates. On the saw side, acrylic makes good zero-clearance insert blanks for hobby saws, clear sled fences, and taper jig bases, though see the caution below.
What thickness to choose
| Use | Thickness | Why |
|---|---|---|
| Small inlay and hinge templates, trim routers | 1/4 in. | Light, easy to clamp, enough for a short bearing |
| General pattern routing, guide bushings | 3/8 in. | Room for a guide bushing collar with margin |
| Large templates, flush-trim bits with tall bearings | 1/2 in. | Stiff, and the bearing rides fully on the template |
| Router base plates | 3/8 or 1/2 in. | Flat and stiff under the motor |
Check your bit: the bearing should ride fully on the template edge, not half on the template and half on the work. Use cast acrylic for templates; it machines more cleanly and is less likely to chip than extruded.
Edges and accuracy
Our lasers cut up to 1/2 in. thick with tolerances around ±0.005 in., which is far tighter than you need for woodworking. Laser edges are glossy and very slightly tapered on thicker sheet. For a template a bearing will follow, a routed (machined) edge is perfectly square and gives the bearing a flat, satin path. Read laser-cut vs router-cut acrylic edges for the details.
- Guide bushing offset: if you'll use a guide bushing, the template must be offset from the final shape by half the difference between bushing diameter and bit diameter. Draw the final shape and tell us the bushing and bit, and we'll offset it, or draw the offset line yourself.
- Inside corners: your router bit can't cut a sharper inside corner than its own radius. Draw inside corners at the bit's radius or larger.
- Inlay pairs: a male and female template set needs the offsets worked out together; send both and note the bit and bushing.
Holes, markings, and handles
We can drill and countersink holes so you can screw the template to the workpiece through waste areas, and engrave centerlines, part names, and the bit and bushing sizes right on the template so you never guess six months later. Engraved lines on clear acrylic show up well when you lay the template over pencil marks. A routed slot or cutout makes a handle for large templates. See acrylic engraving.
Caution: acrylic is not a safety device near a saw blade. It's fine for sled fences and zero-clearance inserts on light-duty saws, but it can crack if a blade or kickback hits it. Keep blade guards in place and use polycarbonate for anything meant to stop debris.
How to order
Draw the template at full size in a DXF or SVG, with holes and engraving on their own layers, and send it through upload a drawing. Simple rectangular jig bases and router plates can go straight into the instant quote. If you've only got a paper pattern, take a photo square-on with a ruler beside it and describe what you need.
Questions
How thick should a router template be?
Thick enough for the bearing or guide bushing to ride fully on the edge: usually 1/4 in. for trim routers and short bearings, 3/8 or 1/2 in. for larger templates and tall bearings.
Will a bearing wear down an acrylic template?
Very slowly. A smooth cast acrylic edge holds up well to bearing contact, much better than MDF. The real risk is nicking it with the bit itself, so set the depth carefully.
Can you make a clear router base plate?
Yes. Send the hole pattern for your router, with countersinks for the screws and the bit opening size, and we'll cut it in 3/8 or 1/2 in. clear acrylic.