Why thick acrylic is routed
We laser cut acrylic up to 1/2 in., and route anything thicker. A router uses a spinning carbide cutter that follows your outline, so the edge comes out perfectly square from face to face, even through 1 in. of material. A laser beam spreads slightly as it goes deeper, which leaves a small taper and visible lines on very thick sheet. At 3/4 and 1 in., routing is the way to get a clean, square, accurate part.
For 1/2 in. sheet we pick the method for the part: the laser for detailed shapes, where its glossy edge saves a polishing step, and the router for big straight-edged pieces such as tabletops and bases, where a square edge that's then polished looks best. If you have a preference, put it in your order notes. For thinner, detailed work, see laser cutting acrylic.
Thicknesses and what they really measure
| Sold as | Made as | Weight per sq. ft. | Colors |
|---|---|---|---|
| 1/2 in. | 12 mm (0.472 in.) | about 2.9 lb | Clear cast, clear extruded, white, black |
| 3/4 in. | 18 mm (0.708 in.) | about 4.4 lb | Clear cast, white, black |
| 1 in. | 24 mm (0.944 in.) | about 5.8 lb | Clear cast |
Thick sheet is cast, and cast sheet varies in thickness across a sheet, often by several hundredths of an inch at these sizes. If your part has to fit a slot or match another piece, tell us and we'll measure the sheet we cut from. See why acrylic is thinner than its label. For weights of a specific part, use the acrylic weight calculator or read acrylic weight per square foot.
Edges on thick acrylic
On thick parts the edge is a big part of what people see, so the finish matters more than on thin sheet. Your options:
- Machined (satin). Straight off the router: square, smooth to the touch, and translucent rather than clear, with faint tool marks. Good for parts that sit in a frame or a slot, and for sump parts where looks don't matter.
- Flame-polished. We machine the edge, then pass a flame over it to melt the surface glossy. Clear and bright, fast enough for curves and outlines, with a slightly rounded look up close. The usual choice for awards with shaped outlines.
- Diamond-polished. A diamond cutter takes a final pass across a straight edge and leaves it nearly as clear as the face of the sheet, crisp and flat. This is the edge you see on high-end awards, display bases, and tabletops. Straight edges only.
- Sanded. An even frosted edge that glows softly when light hits it, and hides fingerprints.
The acrylic edge polishing page explains each finish in more depth. If you plan to polish edges yourself, how to polish acrylic edges covers the steps.
Tolerances
Routed parts are typically within ±0.010 in. (about 0.25 mm) of your drawing on the outline and on holes. Polishing removes a few thousandths of an inch from the edge, which we account for. Edges are square to the face, which matters when you're bonding thick pieces together or stacking them. Holes can be drilled, countersunk, or tapped for machine screws; threads in 1/2 in. and thicker acrylic hold well for fixtures you won't take apart often. See how to tap threads in acrylic.
What people make from thick acrylic
Awards and plaques
3/4 and 1 in. clear acrylic with diamond-polished edges and an engraved logo is the classic corporate award. Reverse engraving on the back face gives the artwork depth. See acrylic awards and plaques and acrylic engraving.
Tabletops and desk tops
A 3/4 or 1 in. tabletop on a metal base looks striking, and it's far lighter and harder to shatter than glass. Be honest with yourself about scratches: acrylic scratches more easily than glass, and fine scratches can be buffed out. Read acrylic vs tempered glass for tabletops before deciding.
Aquarium lids, sumps, and baffles
Thick acrylic is used for sump baffles, overflow boxes, braces, and lids. We cut and drill parts to your drawing. For the main panels of a tank, the thickness depends on the water depth and panel length, and a tank failure is serious, so plan carefully with the aquarium acrylic thickness calculator and acrylic aquarium thickness. See also aquarium baffles and sump dividers.
Risers, bases, and display blocks
Solid acrylic risers and bases lift products, jewelry, and collectibles in retail displays and look clean from every angle. Acrylic risers and display stands has typical sizes.
Shelves and structural parts
Long shelves need thickness to stay flat. A 1/2 or 3/4 in. shelf spans much farther than 1/4 in. before it visibly sags; the shelf sag calculator shows the difference for your span and load. Thick acrylic also makes good bookends, machine windows, and fixtures.
Designing thick parts
- Inside corners have a radius. A router cutter is round, so inside corners come out with a small radius, typically about 1/8 in. If you need a sharp inside corner, tell us; it can sometimes be squared by hand.
- Choose straight edges for the clearest finish. Diamond polishing only works on straight edges. A shape with curves can be flame-polished all around.
- Think about weight. A 24 × 48 in. piece of 1 in. acrylic weighs about 46 lb. Plan the hardware and the base for it.
- Leave room to move. Thick panels expand with heat like thin ones do. Use oversized holes for fasteners; the thermal expansion calculator gives the clearance.
- Bonding thick parts takes flat, square edges, which routing gives you. See how to glue acrylic, or let us build the assembly: acrylic fabrication.
Pricing and lead time
The price depends on the area of sheet your part uses, the thickness, the length of the cut, the number of holes, and the edge finish you pick. Thick sheet costs more per square foot and cuts more slowly than thin sheet, so it's worth choosing the thinnest sheet that gives you the look and strength you need. Enter a size at /quote to see the price instantly, or upload a DXF or SVG at /quote#upload.
Most thick acrylic orders ship in 7 to 10 business days after we confirm them, and rush orders ship in 1 to 3 business days. Thick parts are heavy and get packed with extra care; we'll confirm the shipping cost on your invoice.