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Cast acrylic versus extruded acrylic

Acrylic is produced in two basic versions, cast and extruded. Cast acrylic is produced by mixing the acrylic liquid ingredients in molds. For acrylic plates between two glass plates. A chemical process in the mold create a homogeneous material with equivalent properties in all directions. In contrast, extruded acrylic is produced by continuously pushing acrylic mass through a form, while the chemical process takes place. Extruded acrylic is therefore heterogeneous, with properties which vary depending on the direction. We call it the extrusion direction for acrylic sheets. Cast acrylic is usually regarded as a better quality than extruded acrylic even though it is in fact two different materials with the advantages and disadvantages.The various production methods provide some small but important differences: Acryl
Colored acrylic sheets are usually cast acrylic.
Profiles are extruded acrylic.
  • Chemical Resistance
    Cast acrylic is more resistant to the same solvents.
  • Laser cutting
    When laser cutting extruded acrylic , there will come a burr on one side of the part. On the cast acrylic there is almost no burrs. The edges on extruded acrylic parts can look a bit different depending on the direction of the acrylic extrusion.
  • Laser engraving
    The Laser engraving will on extruded acrylic look matt gray. On the cast acrylic will look matt white.
  • Heat bending and thermoforming
    A sheet of extruded acrylic can, because of the acrylic extrusion direction, behave differently depending on the bending direction relatively to the extrusion. With cast acrylic, it makes no difference.
    When cast colored acrylic is heated for thermoforming or heat bending the color can change. Matt-colored surfaces can become clear and clear surfaces can become matt. In addition, the shade of color can change. Cast acrylic is harder to bend / shape.
  • Thickness tolerance
    Sheets of cast acrylic vary more in thickness. A cast 3 mm acrylic sheet vary +/- 15%. While an extruded sheet only vary +/- 5%. The dispersion within the tolerance also seems to be less on extruded sheets.
    The high tolerance on cast acrylic sheets often comes as a surprise to designers, with many construction errors to follow.
  • Scratch-resistant
    Cast acrylic it more scrats resistant than extruded acrylic.
  • Flame polishing
    Cast acrylic is harder to flame polish.
  • Colors
    Cast acrylic is produced in a many different color and thicknesses. The color selection is more more limited for extruded acrylic. If one order a special color from a supplier, it will in most cases be cast acrylic.
  • Tension
    There is more tension in extruded acrylic.       
A digital luggage tag made of both cast and extruded acrylic.

3 mm white cast acrylic sheet are printed with a digital printer. A round 2 mm deep milling makes room for an acrylic piece with a QR code can be inserted. The tag is laser cut from the sheet.

The QR codes are printed inverted on 1.5 mm clear extruded acrylic sheets. The printed sheets have double adhesive tape applied on the printed side and is then laser cut into circular pieces.

The 2 acrylic parts are glued together with an NFC chip in between.

The product can be purchased from
Tagone luggage tag
Cast extruded laser engraved acrylic
With a CO2 laser both cast and extruded clear acrylic can be laser engraved. The colour of the engraving becomes white on cast acrylic - light grey on extruded acrylic. Note that clear acrylic cannot be laser engraved with a YAG laser.
  Laser cutting
  The use of Acrylic
  Production of sheets and profiles
  Cast versus extruded acrylic
  Chemical resistance
  Structural properties
  Dimensional stability
  Tension and notch
  Printing on acrylic
  Acrylic versus glass
  Acrylic versus polycarbonate
  Trade names for acrylic
  Environmental impacts of acrylics

  how do I get acrylic items cheaply?
  What is tolerance?
  Where can acrylic be bought?
  How big is the heat expansion of acrylic?

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