Acrylite Fabrication Guide

TECH
BRIEF
Fabrication
#1 Handling and Maintenance
This brief gives advice for:
Storage
Marking on Masking
Removing Masking
Caring for ACRYLITE FF sheet
Equipment and Materials Suppliers
Additional Technical Information
and Assistance
Storage
Skids and cases of ACRYLITE FF acrylic sheet are
shipped with polyethylene film overwrap which protects
the sheet from dirt and moisture. The overwrap should
be left intact during storage to minimize warpage.
Acrylic sheet should be stored vertically or in special
racks where the sheet can lean at an angle of approximately 10. These angled racks should have plywood
panels, which give full support to the material.
If ACRYLITE FF sheet is stored horizontally, it must not

be allowed to sag. Care must be taken to prevent chips
or dirt from becoming lodged between the sheet as the
weight of the material can force these chips through the
protective masking and damage the sheet. If various
sizes are stacked horizontally, the larger sheet should
be at the bottom to avoid unsupported overhang.
ACRYLITE FF sheet should not be stored near radiators
or steam pipes or other heat sources, as heat tends to
soften and deform acrylic sheet. Do not store acrylic
sheet near spray painting booths or expose it to other
solvent vapors which may penetrate the masking and
damage the sheet surface.
Marking on Masking
ACRYLITE FF sheet is manufactured with a masking
on both surfaces to protect the sheet from scratching
during storage and handling. Both latex paper and
polyethylene film masking are available.
Paper masking can be marked with almost any writing
tool including pencils, ballpoint pens, and felt tip pens.
Marking on polyethylene masking may be done with
grease pencils and certain felt tip markers. See the
Equipment and Materials Suppliers section of this Tech
Brief.
Removing Masking
The sheet masking should be left in place during most
fabrication operations to protect the sheet surface. The
masking may be removed for intricate detail work on the
sheet if necessary. Certain heat sources used in line
bending and thermoforming operations may also require
removal of the masking. See Tech Briefs for Line
Bending and Thermoforming for details.
Unmasked sheet should be stored in the original
shipping cartons. Avoid handling unmasked sheet
unnecessarily.
Curbell Plastics is a proud supplier of Acrylite materials

$63#&--tXXXDVSCFMMQMBTUJDTDPN
You can remove paper masking with a cardboard tube

by rolling the masking around it. Masked ACRYLITE FF
sheet should be kept away from heat and sunlight, and
masking should be removed soon after installation. If the
adhesive has hardened, moistening it with aliphatic
naphtha, hexane, or kerosene will help to soften it. Do
not use gasoline or sharp-edged objects such as razor
blades. Any oily film left behind by solvents should
be removed immediately by washing.
Caring for ACRYLITE FF Sheet

Washing
Wash ACRYLITE FF sheet with a solution of mild soap
or detergent and lukewarm water. Use a clean soft cloth,
applying only light pressure. Rinse with clean water and
dry by blotting with a damp cloth or chamois.
Grease, oil, or tar may be removed with a good grade of
hexane, aliphatic naphtha, or kerosene. These solvents
may be obtained at a paint or hardware store and should
be used in accordance with manufacturers recommendations.
DO NOT USE: Window cleaning sprays, kitchen
scouring compounds or solvents such as acetone,
gasoline, benzene, alcohol, carbon tetrachloride, or
lacquer thinner. These can scratch the sheets surface
and/or weaken the sheet causing small surface
cracks called crazing.
Dusting
Dust with a soft, damp cloth or chamois. Dry or gritty
cloths may cause surface scratches and create a static
electric charge on the surface (see section on neutralizing static electricity).
Roll the masking paper onto a cardboard tube.
Polishing
Protect ACRYLITE FF sheet and maintain its surface
gloss by occasional polishing with a good plastic cleaner
and polish. Apply a thin, even coat with a soft clean
cloth and polish slightly with cotton flannel. Then wipe
with a damp cloth to help eliminate electrostatic charges
that can attract dust particles.
Neutralizing Static Electricity

A static electrical charge can develop on ACRYLITE FF
sheet during handling and processing. This is not unique
to ACRYLITE FF sheet but is common to many materials, particularly plastics.
When the paper or film masking is stripped off the
acrylic sheet, a static charge is created on the sheet
surface. Static electricity attracts dust, chips, etc.
floating in the air or on nearby work surfaces and holds
these contaminants tightly to the surface. A compressed
air gun will remove some of this surface dirt, but much
of it continues to cling to the sheet. Because the sheet
must be dirt-free before bending, painting or
thermoforming operations, a separate step is required.
Roll the masking paper back enough to allow work

on the edges of the sheet.
To temporarily eliminate the electrical charge on all

plastic surfaces, ionizing air guns can be used. These
guns provide a stream of charged particles. They
effectively neutralize static charges that hold dirt to the
surface. By using ionized air to clean ACRYLITE FF
sheet after the masking has been removed, the sheet
can be directly heated, painted, or otherwise processed.
Because additional cleaning is eliminated, considerable
man-hours will be saved making the economic advantages obvious. The appearance of painted and/or silkscreened sheet is greatly improved by the elimination of
static charges.
Removing Scratches
Several anti-static cleaners for plastics are also available which will reduce static electricity and dust attraction. Wiping with a soft damp cloth or chamois is all that
is necessary to keep ACRYLITE FF sheet dust-free
between applications of these cleaners.
Contact your local Authorized Distributor of ACRYLITE

acrylic sheet for information on available scratch
removal kits.
Fine scratches can be removed by hand polishing. Apply

a plastic scratch remover to a soft flannel pad and rub.
When the scratches have disappeared, remove all
residue and polish. For deeper scratches, first sand
lightly with a 400-grit wet or dry sandpaper, using plenty
of water and rinsing the sandpaper frequently. Follow by
buffing with a clean muslin wheel and a good polishing
compound. For the highest gloss, use a clean-up wheel
made of soft cotton or flannel sections and on which no
compound is used. An electric drill with a buffing wheel
is ideal.

Markers
Anti-Static Cleaners and Polishes
Anit-Static Air Guns
Sharpie
Sanford Corporation
2711 Washington Blvd.
Bellwood, IL 60104
800-323-0749
www.sanfordcorp.com
210 and 210 Plus

Plastic Cleaner
Sumner Laboratories
186 Lincoln St.
Boston, MA 02111
617-542-8656
Fax: 617-482-9001
Plexus Plastic Center

Plexus
638 Lindero Canyon Rd.
#371
Agoura, CA 91301
800-405-6495
Fax: 818-879-0697
www.plexusplasticcleaner.com
20/20 Plastic-Cleaner
Scotch-Brite High
Craftics, Inc.
Performance Cloth
PO Box 91930
Albuquerque, NM 87199 3M Corp Home Care
Division
505-338-0005
2100 Wilson Ave.
Fax: 505-338-0008
St. Paul, MN 55119
www.craftics.com
877-362-5684
Fax: 651-733-0914
www.3m.com
Simco Company
2257 North Penn Rd.
Hatfield, PA 19440
800-203-3419
Fax: 215-822-3795
www.simco-static.com
Additional Technical Information and Assistance

We invite you to visit our
TechKnowlogy Center at www.cyro.com.
Visitors have immediate access to frequently asked
questions, technical concerns, physical properties,
processing conditions, fabrication tips,
regulatory compliance information,
engineering guidelines, tips for
troubleshooting, and hundreds
of other facts about acrylics from
one of North Americas
leading manufacturers of
acrylic-based polymer and
sheet products
Degussa, CYRO Industries

379 Interpace Parkway
PO Box 677
Parsippany, NJ 07054
800-631-5384
Sales
For the name of a local Authorized Distributor,
visit www.cyro.com or call 800-631-5384.
Fire Precautions
ACRYLITE FF sheet is a combustible thermoplastic. Precautions should be taken to protect this material from flames and high heat sources. ACRYLITE FF sheet
usually burns rapidly to completion if not extinguished. The products of combustion, if sufficient air is present, are carbon dioxide and water. However, in many fires
sufficient air will not be available and toxic carbon monoxide will be formed, as it will when other common combustible materials are burned. We urge good judgement in
the use of this versatile material and recommend that building codes be followed carefully to assure it is used properly.
Compatibility
Like other plastic materials, ACRYLITE FF sheet is subject to crazing, cracking or discoloration if brought into contact with incompatible materials. These materials
may include cleaners, polishes, adhesives, sealants, gasketing or packaging materials, cutting emulsions, etc. See the Tech Briefs in this series for more information,
or contact your ACRYLITE Sheet Distributor or the CYRO Technical Center for information on a specific product.
Important Notice
The information and statements herein are believed to be reliable but are not to be construed as a warranty or representation for which we assume legal responsibility.
Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose of any information or products referred to herein.
NO WARRANTY OF FITNESS FOR PARTICULAR PURPOSE IS MADE. Nothing herein is to be taken as permission, inducement or recommendation to practice any
patented invention without a license.
www.cyro.com
2003 CYRO Industries. All rights reserved. Printed in USA.
1319(1J)-0803-10MG
TECH
BRIEF
Fabrication
#2 Cutting with Circular Saws
2. When selecting a panel saw, also be sure that it

provides full and close support under the sheet while the
saw blade is making the saw cut. Some designs of
computer controlled panel saws do not provide
continuous material support. This results in sheet
vibration during cutting and will cause chipping on the
bottom of the sheet, especially with thinner gauge
material. A narrow gap between the saw blade and the
supporting structure is also important for minimizing
vibration.

z
Equipment
Procedures
Trouble Shooting
Equipment Suppliers

and Assistance
3. A solid hold-down system that clamps the material

firmly in place during the cutting operation is also a
necessity. It will help to reduce vibration of the sheet
and improve cutting results. Most panel saws employ a
single rigid hold-down bar with pressure cylinders at
each end for clamping force. Additional pressure
cylinders positioned across the length of the hold-down
bar will provide improved clamping pressure. Some
systems utilize several independent hold-down bars.
These have the advantage of being able to conform to
thickness variations in the material being cut; however,
the gap between bars must be small to prevent material
vibration.
Equipment
ACRYLITE FF sheet is generally cut with overhead
panel saws, beam type panel saws, and table saws. The
saws should have minimal vibration and be powerful
enough to make the required cuts.
Table saws with arbor sizes from 5/8 to 1 in diameter
driven by motors ranging from 3 10 hp are recommended. Direct drive or belt drive systems can be used.
Most table saws provide a saw blade rotation speed of
3,450 rpm.
Panel saws vary greatly in size from small vertical panel
saws for general purpose cutting to large CNC controlled
horizontal panel saws capable of high volume, tight
tolerance cutting. Their drive motors should range in
power from 10 to 30 hp. Saw blade rotation speeds are
typically between 2,000 and 8,000 rpm. Panel saws with
adjustable saw blade speed are available and provide
greater flexibility for achieving an optimum saw cut.
In selecting a beam type table panel saw for cutting
acrylic sheet, the following three considerations are
critical.
1. Be sure the saw offers the ability to easily adjust
blade clearance (or height). This will ensure the necessary flexibility for cutting different thicknesses or
quantities of sheet.
1
If using a table saw, be sure it comes equipped with all

the necessary safety devices. Most table saws come
complete with a blade guard, splitter and anti-kick back
device. Many anti-kick back devices do not work well
with plastics. It may be necessary to consult the
equipment manufacturer for help in selecting a suitable
device. Kick-plate switches and electronic motor brakes
should also be considered for additional safety. As well,
a heavy-duty fence will provide greater stability when
cutting and will last longer.
Saw Blades
With any saw, blade alignment is critical for achieving

good results. The saw arbor, the saw table and the table
fence must be properly aligned to prevent back or
double cutting. Improper alignment can cause crowding
of the material against the back of the saw blade. This
will lead to chipping and melting of the material and on
table saws can result in dangerous kick-back. On table
saws, the blade should be set perfectly parallel to the
miter gauge slots in the saw table. The fence should
also be set parallel to the miter gauge slots or open
slightly at the back (1/32 to 1/64). On panel saws, the
saw blade carriage should be aligned to produce a
square cut and the saw blade rotation must run parallel
to the direction of carriage travel to ensure proper
tracking. Incorrect saw blade alignment can often be
identified by observing the machining marks in the saw
cut edge. For below-table panel saws, the machining
marks should curve downwards in the direction of the
blade travel. If the machining marks on one side of the
cut curve upward in the direction of the blade travel, it
indicates that the saw blade is healing to that side. See
the diagram below.
The optimum number of teeth per blade can vary

depending on the blade size, blade rotation speed and
application, such as gang or single sheet cutting.
Common blade diameters and tooth selections used for
cutting acrylic sheet include:
There are several saw blades on the market that can

effectively cut ACRYLITE FF sheet. Sharp teeth are
essential for achieving good results. Carbide tipped saw
blades are recommended for superior cuts and longer
life of the cutting edge. It is also important to dedicate
saw blades for cutting acrylic only. Cutting other
materials on saw blades intended for acrylic will dull or
damage the blade and lead to poor cutting performance
when the blade is used again to cut acrylic.
10 diameter, 60 and 80 tooth

12 diameter, 60, 80 and 100 tooth
14 diameter 60, 80 and 100 tooth
Proper selection of the saw blade size can be guided by
considering the surface feet/minute (SFM) of the blade
in the saw. The SFM of the blade is the actual speed at
which the teeth are moving. For acrylic, it should be
between 6,000 -14,000 ft/min. To determine the SFM of
the blade use the following formula:
SFM = Diameter (inches) x RPM x 0.262
Example:
10 diameter blade rotating at

3450 RPM
SFM
= 10 x 3,450 x 0.263
= 9,000
The 10 blade size is suitable because the SFM is

between 6,000 and 14,000.
The number of teeth on the saw blade should be
selected to give proper tooth engagement. Between 2 6
teeth should be engaged with the material during cutting.
Engagement of three teeth is considered to be optimum
(one tooth entering the material, one tooth fully engaged,
one tooth leaving the material). A 10-inch diameter,
80-tooth blade is recommended for all-purpose cutting
on a table saw. For recommended saw blade size and
tooth selections, see Table 1.
Run-out (or wobble) of the saw arbor and blade collar

should be essentially zero. Total run out, including the
saw blade, should be less than 0.002. A simple dial
indicator to measure the run-out can be purchased from
industrial hardware suppliers such as Sears.
The width of the throat plate gap (table kerf) should be
kept to a minimum. This will minimize material vibration
(especially with thin gauge sheet) helping to reduce
chipping. Zero-clearance throat inserts are available for
many table saws and should be used whenever
possible. On panel saws, a false tabletop can
sometimes be fastened to the panel saw surface to
provide a narrower throat gap.
* Table saws or beam type panel saws only.
For gang cutting of stacked sheets, a saw blade whose

teeth have increased radial clearance is recommended.
This clearance will reduce carbide/plastic contact on the
sides of the teeth and, therefore, reduce heat generated
by friction. Use ACRYLITE FF sheet masked with
polyethylene masking where possible when gang cutting;
the polyethylene masking acts as a lubricant.
For cutting acrylic, the teeth of the saw blade should

have the triple-chip design, where the cutting edge of
every other tooth is beveled. The beveled tooth, or crown
tooth, removes the material in the center of the cut while
the flat-top raker tooth follows behind, removing material
from the edges of the cut. This results in the production
of three separate chips center, left side and right side
and hence, the term triple-chip design. On some
designs, the flat-top raker tooth also has very slight
bevels along the top side-edges of the tooth. This helps
to reduce chipping by reducing the notching affect
caused by a square cutting edge.
The quality of construction of the saw blade significantly

affects how well it will cut. Quality considerations when
evaluating a saw blade include:
Run out, which should be less than 0.002.
Teeth height, which needs to be nearly constant. Any
variations must be gradual and not abrupt the blade
should have good concentricity.
Teeth positioning, which must all be in the same
radial plane, i.e. one tooth cannot extend to one side
more than the others or chipping will result.
Blade plate quality, which should be tempered to a
hardness of C42 C46 giving it greater rigidity and
resulting in reduced vibration during operation.
Number of blade expansion slots, (4 5 for a 10
diameter blade) which minimize warping when the
blade heats up.
Size of carbide tips. Larger tips mean the blade can
be sharpened more often. Tips will vary in size from
5/32 13/32 long and 1/16 3/32 wide.
Brazing method used to attach the carbide tips to the
plate. Carbide tips may be brazed to the plate by
hand or by machine induction. Generally, machine
induction provides more consistent and reliable
performance.
Best results are achieved when the teeth have a

clearance angle (top clearance) of 10 to 15. This
minimizes contact between the teeth and the material reducing friction and resulting in less melting. The proper
rake or hook angle, 0 to 5 positive, ensures the teeth
do not strike the material too aggressively. Higher angles
can lead to chipping due to poor blade stability and poor
control of material feed rates.
Grinding quality or surface finish of the teeth, which

will determine their sharpness and the quality of the
resulting saw cut. Finer grinding will result in a
smoother finish, leaving less machining marks on the
teeth (visible under magnification) and cleaner,
straighter tooth edges.
Saw blades should be handled carefully with cut
resistant gloves. Avoid impact shocks such as dropping
or hitting the saw blades, as the carbide tips are brittle
and can chip easily. Also, impact shock can bend a
blade, creating melting and chipping as it moves through
a cut. When not in use, blades should be stored on a
properly designed wooden fixture that will protect the
blade from accidental impacts and prevent accidental
contact with its sharp tips.
Saw blades have a maximum rating for rotation speed.
Be sure to verify that the saw being used will not exceed
the limitations of the saw blade that has been selected.
Carbide tipped saw blades should never be operated in
excess of 18,000 SFM.
Feed the material evenly through the saw. Uneven feed

rates will produce melted spots or chipping on the
plastic. Typical feed rates for ACRYLITE FF sheet are
100 to 300 per minute. However, with some specially
designed saw blades (such as the NO MELT saw blade
from Forrest Manufacturing Co.) feed rates as high as
600 per minute can be used with success.
Saw Blade Dampeners/Stiffeners

Saw blade dampeners or stiffeners can greatly reduce
saw blade vibration during saw operation. They are
highly recommended for use when cutting acrylic sheet
because they will usually result in improved saw cut
quality and reduced noise during saw operation. (Note:
Some high quality panel saws are built with large blade
collars and may not benefit from the use of a blade
stiffener.) When installing a stiffener, be sure to remove
all foreign material from the saw blade and mounting
washers. Any bumps or scratch-burrs on the saw blade
surface should be stoned flat to ensure even metal-tometal contact between the stiffener and the saw blade.
Best results are normally obtained by selecting a
stiffener to 2/3 the diameter of the saw blade.
When cutting on a table saw, care must be taken to

ensure the operators safety. Always follow the
precautions outlined in the manual provided by the saw
manufacturer and consult the saw blade supplier for
recommendations on the proper use of their saw blades.
Safety precautions should also include (but are not
limited to) the following:
Always wear protective safety glasses with side
shields.
Cooling
The use of a saw blade cooling system can yield a
much cleaner, smoother saw cut edge and greatly
increase the life of the saw blade. These systems
remove heat from the blade and the plastic as it is being
cut. Two types of systems are commonly used.
Compressed air or vortex tube cooled compressed air
systems are preferred. These systems are cleaner to
operate and require little maintenance. Mist systems,
which apply a water-soluble oil with rust inhibitor, also
work well providing blade lubrication as well as cooling.
However, these systems will require more maintenance
and the material may need cleaning afterwards to
remove residual oil. It is also important to ensure that
the lubricating solution is compatible with acrylic. (See
the Equipment and Material Suppliers section for
recommended lubricants or contact CYROs Technical
Service Department with compatibility questions.) When
using a saw blade cooling system, the air or mist stream
should be lightly sprayed on the teeth of the saw blade
just before they enter the material.
Ensure all guards are in place and operational.

Do not wear loose fitting clothing or jewelry and tie
back long hair.
Ensure work area is clean and free of slip hazards.
Ensure the correct saw blade is mounted for the
material being cut.
Ensure saw blade is in good condition, is properly
mounted, rotates in the correct direction, is correctly
aligned, and is set at the proper height.
Never place hands within four (4) inches of the
rotating saw blade. If small pieces must be cut that
could require the hands to be closer, then consider
alternate methods of cutting, feeding or fixturing the
material for safer handling.
Never force-feed material into the blade. If the motor
slows down, the material begins to ride-up or if
excessive vibration is encountered, discontinue
cutting and turn off the power.
Operation
For table type saws or panel saws with the blade
mounted underneath, the blade should protrude
approximately 1/8 to 1/2 above the work pieces. The
optimum setting will vary with sheet thickness (see
Table 1). On overhead blade-mounted panel saws, the
blade should protrude 1/32 through the material. These
settings should yield a smooth cut and minimize edge
chipping by providing a favorable cutting angle for the
cutting edge of the saw blade teeth. In general, larger
blade clearances will reduce tooth engagement slightly
resulting in less heat generation and, in some situations,
reduced melting while smaller blade clearances provide
better cutting and chip control resulting in less likelihood
of chipping on the bottom of the cut. Excessively low
blade clearances, often in combination with a dull blade,
can cause chipping at the top of the cut.
Never position your body directly behind the saw

blade during operation and be sure no one else is
working in the area behind the blade.
Never utilize the fence for sizing cuts less than 2.0
times the length of exposed saw blade. For shorter
cuts use a miter gauge to guide the material.
Never use the miter gauge and fence together.
Never draw the material backwards during cutting.
Always hold the material firmly while feeding.
Stop the saw frequently to clean up cutoffs and
sawdust. Be sure the saw blade has stopped
completely before cleaning. Do not attempt to
remove waste while the saw is running.
Trouble Shooting
Problem
Chipping
Cause
Sheet vibration
Chipping at bottom of cut:

the clearance of the blade
above the material is too large
Chipping at top of cut: the clearance
of the blade above the material is too small
Feed rate too fast
Incorrect blade style
Incorrect blade size or number of teeth
Rake angle too high
Excessive width of throat plate gap
Blade vibration or wobble
Melting
Defective teeth (broken or out of alignment)

SFM of blade is too low
Misalignment of blade or fence
Blade clearance too small
Feed rate too slow
Incorrect blade style
Insufficient clearance behind cutting edge
of blade teeth (top clearance)
Insufficient radial clearance of blade teeth
(kerf to blade plate clearance)
Dull blade
Incorrect blade size or number of teeth
SFM of blade too high
Misalignment of blade or fence
Solution
On table saws, hold stacked sheet firmly while feeding. If gang cutting,
hold sheets tightly together by clamping or taping them together.
On panel saws, ensure sheet is fully supported underneath and that
the sheet is being firmly held down across the entire cut.
Reduce clearance
Increase clearance
Decrease feed rate
Use carbide tipped, triple chip design, saw blade
Use recommended blade size and tooth selection
Rake should be 0 to + 5
Replace throat plate
Clean collar and measure blade run out. Employ a blade stiffener.
Replace blade with stiffer, higher quality blade.
Replace blade
Increase RPM or blade size
Verify that saw blade and fence are properly aligned
Adjust clearance
Increase feed rate
Use carbide tipped, triple chip design, saw blade
Clearance behind cutting edge of blade teeth
(top clearance) should be 10 to 15
Use a blade with increased radial clearance on the teeth
Replace blade
Use recommended blade size and tooth selection
Reduce RPM or blade size
Verify that saw blade and fence are properly aligned

The suppliers below offer materials and equipment suitable for use with ACRYLITE FF sheet.
Authorized ACRYLITE sheet distributors may also offer some materials and equipment.
General International
Forrest Manufacturing
Table Saws
Saw Blades
514-326-1161
Co., Inc
Porter Cable-Delta
General
Canada
457 River Road
4825 Highway 45 North
Co., Inc
835
Cherrier
Clifton, NJ 07014
Jackson, TN 38302
457 River Road
Drummondville
Quebec
800-733-7111
800-438-2486
Clifton, NJ 07014
Canada J2B 5A8
Fax: 973-471-3333
www.portercable.com
800-733-7111
819-472-1161
Fax: 973-471-3333
Stiffeners
Powermatic and Jet Tools
Fax: 819-472-3266
General Saw Corp.
(WMH Tool Group)
Panel Saws
2518 Andalusia Blvd.
427 Sanford Road
Co., Inc
Cape Coral, FL 33909
Lavergne, TN 37086
Plastisaw Systems
457 River Road
800-306-SAWS (7297)
800-248-0144
2950 Bay Vista Court
Clifton, NJ 07014
Fax: 941-574-5328
Fax: 615-793-8905
Benecia, CA 94510
800-733-7111
www.gensawcorp@generalsaw.com Fax: 973-471-3333
Altendorf America
707-746-5085
Division of Stiles Machinery www.metlsaw.com
Saw Sharpening
Dial Indicators
3965 44th St.
Schelling America, Inc. North American Products
Grasche USA, Inc.
Grand Rapids, MI 49512
301 Kitty Hawk Drive
Corp.
240 Performance Dr. SE
616-698-7500
Morrisville, NC 27623
1180 Wernsing Road
Box 1348
Fax: 616-698-6997
919-544 0430
Jasper, IN 47546
Hickory, NC 28603-1348
www.stilesmachinery.com
Fax: 919-544-0920
800-634-TOOLS (8665)
828-322-3253
Holz-Her U.S., Inc.
www.schelling.com
Fax: 800-457-7458
www.grasche.com
5120 Westinghouse Blvd.
Giben America, Inc.
www.naptools.com
The L.S. Starrett Co.
Charlotte, NC 28273
3044 Northwoods Circle
121 Crescent Street
704-587-3400
Norcross, GA 30071
Athol, MA 01331
Fax: 704-587-3419
770-448-9140
978-249-3551
www.holzher.com
Fax: 770-448-9133
Fax: 978-249-8495
www.giben.com
www.starrett.com
Continued
5
Cooling Systems
Mist Systems
Lubricants
Vortex Tubes
Exair Corporation
1250 Century Circle North
Cincinnati, OH 45246-3309
513-671-3322
Fax: 513- 671-3363
www.exair.com
LSP Industries
2511 20th Street
Rockford, IL 61104
815-226-8090
Fax: 815-226-9250
www.lsp@lspind.com
Oakite Fisan LC55

Chemetall Oakite
50 Valley Road
Berkeley Heights, NJ 07922
800-526-4473
908-464-4658
www.oakitestore.com
Additional Technical Information and Assistance

We invite you to visit our
TechKnowlogy Center at www.cyro.com.
of other facts about acrylics from
one of North Americas
sheet products.
Degussa / CYRO Industries

.
PO Box 677
800-631-5384
Sales
For the name of a local Authorized Distributor,
visit www.cyro.com or call 800-631-5384.
Technical Service
For more information or specific questions about your project,
contact CYROs Technical Service Center.
Fire Precautions
sufficient air will not be available and toxic carbon monoxide will be formed, as it will when other common combustible materials are burned. We urge good judgement in
the use of this versatile material and recommend that building codes be followed carefully to assure it is used properly.
Compatibility
may include cleaners, polishes, adhesives, sealants, gasketing or packaging materials, cutting emulsions, etc. See the Tech Briefs in this series for more information,
or contact your ACRYLITE Sheet Distributor or the CYRO Technical Center for information on a specific product.
Important Notice
www.cyro.com
1319(2G)-0603-10MG
Fabrication
TECH
BRIEF
#4 Drilling
Equipment
Procedures
Trouble Shooting
Equipment Suppliers

and Assistance
Equipment
Drills
Any commercially available, power-driven equipment is
acceptable. This includes portable drills, drill presses,
lathes, automatic multiple-spindle drilling units, CNC
routers and machining centers.
1. Tip angles on standard drill bits are commonly

118-130. This point angle must be ground to
60-90. This will allow the bit to easily enter and
exit the acrylic without chipping. Larger tip angles
commonly cause cracking and blow out as the bit
exits the sheet. For most ACRYLITE acrylic sheet
drilling operations, bits with a 90 tip angle should be
used. A bit with a 90 tip angle will generate smaller
chips which are easier to evacuate, reducing melting
and improving hole quality. Care must be taken at
the points of entry and exit. Generally, bits with a
90 tip angle are recommended. Bits with 60 tip
angles are also used, especially for holes with
diameters of
1/2" and greater.
Drill Bits
Several manufacturers offer drill bits designed especially
for plastics. Drill bits are commonly made of high-speed
steel (HSS), cobalt, HSS with carbide tips or solid
carbide. Metal-working high-speed steel twist drill bits
can be used with some modification.
Standard metal-working drill bits are designed to
aggressively cut into metal as they are fed into it. If
used on acrylic without modification, these bits will chip
and cause other damage to the plastic. These drill bits
must be reground in order to scrape the plastic instead
of sharply cutting into the material and gouging it. There
are three points to consider when modifying a standard
metal-working twist drill for plastics.
2. The cutting edge must be ground flat to a 0-4 rake

angle. This cutting edge will scrape the acrylic, not
gouge it.
The helix angle on a bit is the angle between the cutting

edge and a vertical line along the center of the bit. Bits
with a moderate helix angle aid in chip ejection and are
recommended for drilling of plastics. Small helix angles
interfere with chip ejection, increasing melting. Helix
angles, which are too large, can cause cracking around
the hole edges. Typically a helix angle of 15-30 is
recommended.
Helix Angle
3. The surface behind the cutting edge must be ground

away to clearance angles of 12-15. This back relief
reduces metal/plastic contact and heat build-up.
This modification is standard on most high quality
twist drill bits.
Procedures
Be sure to follow the manufacturers safety recommendations for equipment and materials used with
ACRYLITE FF acrylic sheet.
Bit geometry affects the quality of drilled holes since it

affects chip size and chip evacuation. Larger diameter
bits and bits with smaller tip angles produce larger chips.
If hole depth (H) is less than bit diameter (D), large chips
are easily ejected. As the depth of the hole increases,
i.e. H>D, larger chips become more difficult to eject
because of the close clearance between the bit and the
hole walls. Increasing bit tip angle decreases the size of
generated chips, facilitating chip ejection. However, as
mentioned above, if the tip angle is too large, larger than
90, blow out and chipping may be a problem when the
bit exits the acrylic.
When drilling ACRYLITE sheet, heat is generated due to

the close clearance between the bit and the hole walls
and because of the difficulty of chip ejection. As mentioned above, chip ejection becomes more difficult as
the hole gets deeper. Friction between the bit and the
material also increases because of acrylics relatively
low thermal conductivity and high thermal expansion
coefficient, which cause the material to expand. These
factors, if not accounted for, can cause the material to
melt and gum, giving less than optimum hole quality. It
is therefore essential to reduce generated heat and to
remove chips quickly.
The work piece should be held firmly or, preferably,
solidly clamped to the worktable. It is best to backup
the piece being drilled with acrylic, other thermoplastic
sheet or medium density fiberboard (MDF) so the drill bit
will continue on into solid material as it penetrates the
bottom surface. This will prevent chipping of the bottom
surface. Use a slow feed rate when starting the drilling
action to allow the bit to enter the material, and also
slow the feed rate as the bit exits the bottom surface to
prevent chipping.
Suggested Drilling Conditions

Appropriate drilling conditions are a combination of both spindle rotation speed (RPM) and feed rate
(IPM). Two parameters are usually employed for determining these. They are:
SFM (surface feet per minute) - the speed at which the cutting edge of the drill bit strikes the
material.
IPR (inches per revolution) - the amount of material being removed per revolution of the drill bit,
also referred to as chip load.
The SFM and IPR cannot be directly set on manually operated drilling equipment. However, SFM and
IPR data can be used to determine proper settings for spindle rotation speed in RPM (revolutions per
minute), and feed rate in IPM (inches per minute). If the optimum SFM and IPR are known, then the
settings can be determined using the following equations:
For drilling acrylic the recommended values for SFM and IPR are given in Table 1 below.
Table 1: Recommended values for SFM and IPR

Diameter of bit (in.)
1/16
1/8
1/4
3/8
1/2
3/4
1
SFM
20-160
20-160
20-160
20-160
30-90
30-90
30-90
IPR
0.001
0.002
0.004
0.006
0.008
0.010
0.012-0.015
These recommended values can be used with the above equations to determine drilling settings.
Alternatively, figures 1, 2, and 3 provided below and on the next page can be used.
Figure 1: Spindle Speed recommendations (RPM) for drilling acylic (D=0.063"-0.375")
Figure 2: Spindle Speed recommendations (RPM) for drilling acylic (D=0.380"-1")
Figure 3: Feed rate (IPM) recommendations for drilling acrylic
As indicated in the graphs and table above, lower SFMs

are required for larger drill bits. This is to ensure
smooth, vibration-free drilling because large bits will tend
to grab the material more. As a result, feed rate must
generally be slowed down in order to prevent chipping
and consequently spindle speed must be reduced to
prevent melting.
It is difficult to precisely control feed rate in manual

drilling operations. Hole finish can be used as a guide
for appropriate feed rates once the correct RPM is
established. If the material chips, feed rate is too fast
and must be decreased. If the material melts, feed rate
is too slow and must be increased.
For H>D, peck drilling, drilling in increments and removing the bit from the material periodically to clear chips,
should be employed.
The shape of chips generated from drilling can serve as

a guide for drilling conditions. Optimum conditions result
in smooth surface holes with smooth, continuous chips.
If chips are crumbly and the cut is uneven, the feed rate
is too high or RPM is too low. Chips that are molten and
holes that show melting indicate that feed rate is too low
or RPM is too high.
Manual Drilling
Manual drilling operations should be performed at slower
speeds and feed rates than automated or CNC drilling,
taking into account the diameter of the bit, material
thickness, and ability to cool during drilling. Additionally,
peck drilling should be employed in deeper holes to
reduce melting.
4
Shape of Chips
Coolants
Deburring and Countersinking
Air or liquid coolants should be used whenever possible.

Coolants reduce generated heat, and therefore improve
hole quality. In certain hole depths and sizes, coolants
are necessary to prevent melting. As a general rule,
coolants should be used when the depth of the hole (H)
exceeds bit diameter (D) (e.g. for D=0.250", a coolant
should be used for H>0.250"). Coolants should also be
used for holes greater than or equal to 1/2" in diameter
(D 1/2").
Holes which may be subject to forces from screws or

bolts should be deburred with a countersink. Zero flute
countersinks work well for the countersinking and
deburring of holes in acrylic sheet. If a countersink is
unavailable, use a drill of larger diameter than the hole
and deburr the rough edge on the exit side of the hole
(side where the drill came through the sheet).
Cold air guns provide good cooling and are usually

cleaner to use than liquid coolants. However, liquid
coolants provide more cooling, as the liquid can trickle
down the hole as the bit goes through the material,
resulting in better hole finishes. Water, kerosene,
mineral oils and other compatible solvents can be
used.
Circuit Board Drilling
Figure 4: Spindle speed (RPM) recommendations for acrylic circuit board drilling
Circuit board drilling is a special

case where automated machines
drill thousands of tiny holes at very
high speed. Specially designed bits
are required. Feed rate and RPM
recommendations are provided in
figures 4 and 5.
Figure 5: Feed rate (IPM) recommendations for acrylic circuit board drilling
Drilling Large Holes

To drill a hole in ACRYLITE FF sheet greater than 1
(25.4 mm), a circle cutter may be used. The cutter bit
must also be modified to accommodate the material
properties of acrylic. The tip must scrape the acrylic,
not gouge it. For optimum cutting with circle cutters
consider the following recommendations:
The fly cutter and cutting tool itself must be secured
properly. Cutting tool must only be extended enough
to achieve the desired depth of cut.
ACRYLITE FF sheet must be adequately supported
and clamped to prevent flexing or vibration during the
cutting operation. The material should also be placed
as close to the fly cutter as possible to reduce the
distance the cutter has to travel.
A spindle speed of between 400-600 rpm is
recommended.
A slow, steady feed rate is very important to achieve
a clean, smooth hole. When the hole has been
completed and the blank has freed itself, turning the
drill press off without removing the cutter, is desirable
in order to prevent any chipping of the hole during
tool exit.
A light misting of water is also recommended to keep
the cutter and plastic cool, and also to act as a cutting
lubricant.
For information on the proper cutter bit specifications

contact CYRO Industries, Technical Service at
(203)-795-6081.
CAUTION: A circle cutter should only be used in a drill
press with the acrylic sheet securely clamped to the
machine table. The drill press provides the uniform
pressure and constant positioning essential for a safe
drilling of quality holes. Never attempt to use a circle
cutter with a hand-held electric drill.
Drilling - Onsite Installations

The previous sections dealt with controlled production
and shop applications. Understanding this information is
invaluable for many hole making requirements. Additionally there are times that holes need to be made, such as
at a job site, where there is limited control of the exact
speeds and feeds that are being used. In these situations, the following bit recommendations may be helpful.
Several drill bit geometries are described below that can
be used with success, although most do not leave the
inside diameter of the hole with a smooth finish. These
bits require the same considerations for support behind
the sheet and for cooling as previously reviewed for
twist drills bits.
Spade Bit (2" to 1-1/2") - use an advanced design
such as the Irwin SPEEDBOR 2000 which has
spurs on the outer edges to aid in alignment and
provide smooth break through when the bit exits the
material.
Brad Point Bit (1/8" to 1") - this design is similar to
a twist drill with a modified tip similar to a spade bit
with spurs. It has an advantage over a spade bit
because it has a helical flute design which will pull
out chips.
Unibit or Vari-Bit Step Drill (1/8" to 1/2") - these
bits can be used for sheet up to 0.118" (3 mm) thick
to achieve a variety of hole diameters with a single
bit. They require maximum support behind the sheet
during use to prevent cracking.
Hole Saws w/center pilot drill arbor (3/4" to 6") these require cooling while cutting to prevent stress
build up in the sheet. They leave a poor finish on the
inside of the hole. They are useful for rough passage
holes for installation of HVAC, plumbing or electrical
wiring.
Trouble Shooting
Problem
Cause
Solution
Chipping
Feed rate too fast
Reduce feed rate
Rake angle of bit too large
Rake angle should be 0 to 4
Sheet vibration
Clamp sheet tightly and use solid backing
Drill bit wobble
Replace bit or chuck
Feed rate too slow
Increase feed rate
RPMs too high
Reduce RPMs
Heavy chip load
Clear chip buildup

Increase twist angle of bit
Insufficient coolant
Increase coolant (water) supply
Clearance angle too small,

(not enough back relief)
Regrind drill bit to 12 to 15

clearance angle
Drill bit is not true
Regrind drill bit
Bent drill bit
Replace bit
Worn chuck
Replace chuck
Worn spindle
Replace spindle or spindle bearings
Melting
Irregular Hole

The suppliers listed below offer materials and equipment tested and approved by CYRO Industries. Authorized
ACRYLITE Sheet Distributors may also offer materials and equipment. Visit www.cyro.com for a list of authorized
CYRO sheet distributors.
Plastic Drill Bits
Standard Drill Bits
Circle Cutters
Onsrud Cutter, Inc.

80 Liberty Drive
Libertyville, IL 60048
800-234-1560
Fax: 800-557-6720
www.onsrud.com
Craftics, Inc.
2701 N. Pulaski Rd.
Chicago IL 60639
773-235-3307
Fax: 800-289-2020
www.craftics.com
American Tool Co.
92 Grant Street
Wilmington, OH 45177-0829
800-866-5740
Fax: 937-382-8199
www.americantool.com
High Speed Steel Drill Bits:

Local Hardware Store
Woodworking Industry Magazine
General Tools Manufacturing Inc.

80 White Street
New York, NY 10013-3567
212-431-6100
Fax: 212-431-6499
www.generaltools.com
Ralmikes Tool-A-Rama
4405 S. Clinton Avenue
S. Plainfield, NJ 07080
800-462-4243
800-472-5645
www.ralmikes.com
Stanley Tools
Division of Stanley Works
1000 Stanley Drive
New Britain, CT 06053
860-225-5111 or
1-800-648-7654
Fax: 860-827-3895
www.stanleyworks.com
Solid Carbide Bits

Check the Thomas Register of
American Manufacturers or the Yellow
Pages for your local tool supplier
Zero Flute Countersinks

J & L Industrial Supply
31800 Industrial Road
Livonia, MI 48151
800-521-9520
Fax: 800-525-6817
www.jlindustrial.com
Weldon Brand
Sold through J&L Industrial Supply
For additional information contact:

Technical Service
ForInterpace
more information
379
Parkway, or specific questions about
your
project,
contact NJ
CYROs
Technical Service
PO Box 677, Parsippany,
07054-0677
Representatives.
800-631-5384
www.cyro.com
CYRO Industries
www.degussa.com
CYRO Canada Inc.

6285 Northam Drive
25 Executive Blvd.
Suite 100
Orange, CT 06477
CYRO Industries is a wholly-owned subsidiary of Degussa.
Mississauga,
203-795-6081
Ontario L4V 1X5
905-677-1388
800-268-4743
Sales Offices
For the name of your local Authorized Distributor,
call 800-631-5384, visit www.cyro.com, or contact
the nearest regional sales office:
Eastern Region
100 Enterpise Drive
PO Box 5055
Rockaway, NJ 07866
973-442-6130
Western Region
3180 Crow Canyon Place
Suite 240
San Ramon, CA 94583
925-866-9300
South/Central Region
101 East Park Blvd.
Suite 1039
Plano, TX 75074
972-424-6830
CYRO Canada Inc.

6285 Northam Drive
Suite 100
Mississauga,
Ontario L4V 1X5
905-677-1388
800-268-4743
Web site: www.cyro.com

and Assistance
We invite you to visit our TechKnowlogy Center
on www.cyro.com.
processing conditions, fabrication tips, regulatory
compliance information, engineering guidelines, tips
for troubleshooting, and hundreds of other facts about
acrylics from one of North Americas leading
manufacturers of acrylic-based
polymer and sheet products.
Fire Precautions
ACRYLITE FF sheet is a combustible thermoplastic. Precautions should be
taken to protect this material from flames and high heat sources. ACRYLITE FF
sheet usually burns rapidly to completion if not extinguished. The products of
combustion, if sufficient air is present, are carbon dioxide and water. However,
in many fires sufficient air will not be available and toxic carbon monoxide will
be formed, as it will when other common combustible materials are burned. We
urge good judgement in the use of this versatile material and recommend that
building codes be followed carefully to assure it is used properly.
Compatibility
Like other plastic materials, ACRYLITE FF sheet is subject to crazing, cracking
or discoloration if brought into contact with incompatible materials. These
materials may include cleaners, polishes, adhesives, sealants, gasketing or
packaging materials, cutting emulsions, etc. See the Tech Briefs in this series
for more information, or contact your ACRYLITE Sheet Distributor or the CYRO
Technical Center for information on a specific product.
Important Notice:
The information and statements herein are believed to be reliable but are not to
be construed as a warranty or representation for which we assume legal
responsibility. Users should undertake sufficient verification and testing to
determine the suitability for their own particular purpose of any information or
products referred to herein. NO WARRANTY OF FITNESS FOR PARTICULAR
PURPOSE IS MADE. Nothing herein is to be taken as permission, inducement
or recommendation to practice any patented invention without a license.
1319(4E)-1001-5RA
2001 CYRO Industries. All Rights Reserved. Printed in USA.
Fabrication
#5 Routing
Equipment
Procedures
Trouble Shooting
Equipment Suppliers

and Assistance
Equipment
Manual Feed Routers
Many commercially available types of routers are
acceptable. These include hand held routers, table
routers, pin routers and fixed position routers. The router
should have a minimum of one horsepower and a no
load speed of 20,000 RPM.
CNC (Computer Numerical Controlled)

Routers
Computerized Numerical Control (CNC) machines are
available from several manufacturers for high volume
production. Today there are many companies manufacturing CNC routers servicing industries that fabricate
wood, metal and plastic products. As a result, a variety
of machine designs are available to fit the job demand.
Light duty routers made for engraving or routing thin
(.118") single sheet, are commonly fitted with one to
three horsepower spindle motors. Medium duty routers
as seen in the sign industry use four to seven horsepower motors. Large volume and multiple head routers
have motors ranging from seven to twenty horsepower.
TECH
BRIEF
There are three basic machine designs:
Gantry type machines have an overhead beam that
supports one or more routing heads or motorized
spindles on a column. The column can be programmed
to travel along the gantry beam both horizontally and
vertically. The beam itself rides on two vertical supports
that travel along parallel tracks set on both sides of a
stationary worktable. This facilitates a third axis of
movement.
Stationary bridge machines are similar to gantry type
machines except that the bridge is stationary. The third
axis of movement is facilitated by a worktable that can
move in a horizontal plane perpendicular to the stationary bridge.
Machining centers originate in the tool industry. They
offer higher precision and are commonly used for the
production of small component parts. These machines
typically have smaller worktables than the stationary
bridge or gantry machines and carry a higher price,
corresponding to their accuracy and versatility.
All of these CNC machine types are available for
purchase with hardware and software to facilitate
machining on 2 , 3, 4 and 5 axis. There are machines
suitable for any requirement from fabrication of small
prototypes to large part production runs. CNC machines
can handle repetitive production cycles, using one or
two tables. They are also available with multiple routing
heads or spindles, so several parts can be produced at
the same time. Options such as turret heads and tool
changing spindles to facilitate tool changes without
stopping the machine are available. CNC machines can
be set up for semi-automatic or fully automatic operations that incorporate material pallet changers and
automated loading and unloading equipment.
If business demands justify a step up in production,
CNC routing is one of the best ways to increase productivity, as well as assure reproducible results and quality.
Router Bits
Router bits may be made of high-speed steel (HSS), carbide-tipped, solid carbide or diamond-tipped. They
can be one piece, multiple part, bearing guided, straight cutting, forming or specialty bits.
Router bits for machining acrylic may consist of one to three flutes. Single and double fluted bits are commonly
used. When using HSS or brazed carbide bits, the length of the cutting edge should not exceed three times the
diameter of the tool or a ratio of 3 to 1. With the proper use of solid carbide bit technology, this ratio can be
increased to 4.5 to 1. Bit shank diameter should always be equal to or larger than the cutting tool diameter. The
length of the shank should be long enough so that the entire cutting edge is usable. Bits should be mounted in a
clean collet chuck and set to allow maximum tool bit support and flute clearance to facilitate chip ejection.
For hand held routing, two-flute straight bits are usually recommended.
For table routers, pin routers and fixed position routers, single-flute or two-flute bits can be used. Single flute
straight bits will give good results when contour routing. Single or double flute up-spiral bits will produce better
results when cutting grooves or channels since the up-spiral configuration will assist in removing chips. Both O
flute and V flute geometries work well.
When processing acrylic using a CNC router, solid

carbide, up-spiral O flute router bits will produce the
best results. They are available with one, two or three
flutes. Common bit sizes are 1/8" to 1/2" diameter.
These bits are less susceptible to friction and heat build
up because the O-flute design allows chips to curl
naturally as they are formed and facilitates better
evacuation of the chips from the cutting area. In less
demanding applications, standard twist bits (V-flute
geometry) can also be used with success.
hold the template to the material and moved when

necessary. Templates can be made from plywood,
fiberboard or rigid plastic. A hand-held router can be
piloted around the pattern in several ways. Offsets can
be calculated making allowances for the router subbase, template guide, or a piloted bearing follower bit.
In general, up-spiral bits are recommended because

they pull chips up and out of the way, reducing frictional
heat build-up. However, when material hold down is an
issue, straight flute or down-spiral geometries may be
beneficial. Increasing the number of flutes on the bit will
usually result in a better quality finish on the edges of
the routed surface. However, tooling cost also increases
with the number of flutes on the bit. Therefore, it is best
to start with a one or two flute bit and only step up to a
higher number of flutes if necessary.
Tools with a single flat-faced cutter are commonly
employed for engraving applications. These include
profile cutters, parallel cutters and braille cutters.
Rigidity is important so solid carbide tools should be
used. When engraving letter widths greater than 0.060",
other router bit types may be necessary to provide the
desired finish on the inside of the letter. These include Vgrooving, veining, up-spiral ball nose and double-edge
bottom surfacing bits.
Tool Maintenance
The cutters should be kept sharp. Chipping or overheating will occur with a dull cutter. Both will impart stress
into the sheet.
Procedures
Be sure to follow the manufacturers safety recommendations for equipment and materials used with
ACRYLITE FF acrylic sheet.
Safety
When using routing equipment always wear protective
face shields or safety goggles. Hearing protection is
recommended for extended periods of routing. If a
vacuum system is not used, a respirator or dust mask
will offer protection from dust particles.
Hand Routing
Prototype and replacement parts can be produced using
a hand router. The router is guided around a precut
template pattern that is fastened to the acrylic sheet.
The template is typically held to the sheet using vacuum
or two-sided adhesive tape. Clamps may also be used to
Circle Routing
Circles of varying diameter can be fabricated with a
cutting fixture consisting of a fixed position router and a
sliding adjustable rotary table. The adjustable table is
mounted on a sliding shaft and column. This can be
adjusted for variable center distances. The sheet is held
on the rotating table with vacuum. Once set up, the
sheet is moved into the cutter and rotated 360 to
machine the circle. This method allows for easy machining and size adjustment. It can also be adapted to
machine other shapes by following a pattern. Circles can
also be cut using a hand router and precut circle templates.
Pin Routing / Overhead Routers

Pin routing machines are very versatile. Pin routers
utilize a horizontal column to support a pneumatically
activated guide pin. This pin is set directly over a spindle
which holds the router bit below the worktable. Both the
pin and router bit are fed to a preset stop and are
activated by a foot pedal. Plunge routing can be accomplished using this feature. The template has the material
to be machined fastened below it. An operator feeds the
template along the table to the pin and then guides the
top edge of the template along the pin. As the template
is rotated 360 around the pin, the rotating router bit cuts
the material fastened below the template. The material is
commonly fastened to the template using double-stick
tape or vacuum. Overhead routers work in the same
manner with the router and pin locations inverted.
Contour Routing
Pin routing machines may also be used for multiple part,
stepped or contoured part manufacture. To accomplish
this a contour jig must be employed. The desired pattern
is cut on the base of the contour jig to match a depth
stop preset below the worktable. Several pieces of
material are secured to each other to form a stepped
template. The cutting tool is then guided by a series of
step pin stops set below the worktable. These pins
control the cutting depth of the router bit. The process
does not cut all the way through the sheet. The material
is only separated following the final cut. This multi-cut
process enables the cutting of contoured patterns.
Engraving
Machining ACRYLITE FF sheet using engraving bits
requires the correct spindle speed (RPM), feed rate
(IPM) and depth of cut. The ability to remove chips and
keep the sheet cool while cutting is a key consideration
when engraving. Speeds should be set at 9,000 to
10,000 RPM and feed rates at 55 to 65 IPM. In general,

chip loads (IPT) of 0.003" to 0.006"/tooth should be
used for engraving applications (refer to the Operation
Terminology and Formulas section for more details).
Machines will vary in performance so this information
should only be used as a starting reference.
Computerized Numerical Control (CNC) Routing

Machine Characteristics and Fixturing
In order to optimize machining on a CNC router, there
are several key points to consider. The first is the
machine type and condition. This includes the integrity
of the spindle, the selection and condition of the collets,
the machine table and the fixturing. The quality of the
equipment and fixtures being used will have a significant
impact on the rate at which parts can be processed and
the quality of the finished parts.
Fixturing or part hold down will change with the part
design and size. The most common way of holding
material on a CNC routing table is by using vacuum to
hold parts onto a spoilboard base. Spoilboard is a
medium density fiberboard (MDF) that can be machined
or milled to facilitate part hold down. The two types
commonly used are: Conventional Vacuum Spoilboard
and Universal Vacuum Spoilboard.
Conventional Vacuum Spoilboard is used in conjunction with a high vacuum, low volume pump. Generally
fixtures are specially designed for the parts being
processed and therefore different fixtures are required
for each part design. Fixtures are made by machining
grooves into the spoilboard to supply vacuum to the
part. A gasket is usually attached to the spoilboard just
inside the outer contour of the part to help maintain a
good vacuum seal between the part and the spoilboard.
This type of fixture provides the greatest holding force
for the part.
Universal Vacuum Spoilboard is used in conjunction
with a low vacuum, high volume pump to provide
vacuum through the pour structure of the entire
spoilboard. Material laid on the spoilboard will be held in
place once the vacuum is turned on. The advantage of
this board is that it does not require grooves to direct the
vacuum or gasket to ensure a good seal. As a result, a
single spoilboard base can be used for many different
part designs. Universal vacuum spoilboards are not
recommended for working with small parts or parts with
rough surfaces.
Other methods of part hold down include: bolting down

the material, using cam lock clamps, and holding the
work in a vice that is bolted to the router table.
Processing Parameters
The part requirements and how they impact processing
must be considered. Knowing the depth of cuts to be
made, the minimum inside radius required on the
finished part and the edge finish quality requirements
will guide the selection of tooling and processing parameters. Typical processing parameters will include the
number of tool bit passes chosen to complete the part
and whether or not the part needs to be roughed to
shape before finishing passes are made to achieve the
desired finish.
Machine horsepower and work hold-down (or fixturing)
are the two factors affecting the amount of material that
can be removed during each cutter pass. When multiple
passes are required, start with a large diameter roughing
cutter to remove the bulk of the material. Keep the part
minimum inside radius in consideration for secondary
and/or finishing passes. In most cases, two cutters are
used to machine parts to shape, one for roughing and
one for finishing. In some cases, three cutters may be
required to complete the part and achieve the desired
edge finish and inside radius.
For determining the depth of cut (DOC) to make on each
pass, the following guidelines can be used:
Face Milling
Use a material removal ratio of 3:2. For example if the
cutter diameter is 3", then a 2" cut is the maximum
depth of material that can be removed per pass.
Routing/Periphery Milling
Start with a 0.100" depth of cut per pass and increase
the DOC to 1/2 - 2/3 the cutter diameter. Note: The cutter
edge length (CEL) listed by the cutter manufacturer may
be fully engaged as required. Many single flute up-spiral
and center cutting bits can be plunged or programmed to
ramp in and take the full cutter diameter for slotting and
part cut out. The DOC for a finishing pass should be no
less than .010" and provide a chip load of at least 0.004"
/tooth (refer to the section Operation Terminology and
Formulas for more details).
Operating Conditions
Once the optimum processing parameters have been
determined, consideration must be given to the operating conditions for the CNC router. This includes settings
for the spindle speed and cutter feed rate through the
material. Rotational speeds of 16,000 to 18,000 revolutions per minute (RPM) and feed rates of 100 to 300 per
minute (IPM), normally produce the best results with
1/4", 3/8" and 1/2" diameter bits.
For smaller bits (1/8" and 3/16") rotational speeds of
18,000 to 20,000 RPM, with feed rates of 100 to 200
IPM range will produce the best edge and tool life.
It is important to note that dust/chip collection systems
as well as coolants such as compressed air, mist
coolants and cold air/vortex tube technology, will greatly
reduce the heat build up and improve the quality of the
edge as well as extend the life of the tool.
Direction of Travel
Proper feed direction is essential for a smooth cut.
Routers rotate clockwise when viewed from the spindle
or colleted side of the router. This is also referred to as
Right Hand Cutting. If a hand held router is fed into the
sheet in a clockwise direction, the cutting edges of the
bit will pull the bit into the work rendering control nearly
impossible. This routing method is referred to as Climb
Cutting. Climb Cutting should only be used on machinery
that has rigid spindles and worktables that are free of
leadscrew backlash. Climb Cutting will improve product
surface finish and increase tool life.
Note: This type of machining can only be done on CNC
machinery. Climb Cutting is not recommended for most
routing applications.
The feed direction for external cuts should be counterclockwise. When routing inside edges, the router should
be fed clockwise. This practice will allow an operator to
maintain proper control of the router and attain a smooth
edge. This method is referred to as Conventional Cutting.
Note: Conventional Cutting is the recommended method
for most routing operations. Refer to the routing direction
diagram on page 6.
edge. Cutter diameter is normally dictated by the design

of the part. The key consideration is material removal.
Initial machining steps should employ the largest cutter
diameter to rough out the part. Secondary cutting
operations should utilize bits that match the proper
radius or leave the required edge and surface finish on
the sheet.
Speed Surface Feet Per Minute (SFM) is the actual
speed at which the cutting edge of the tool is striking the
material. It is used to determine spindle revolutions per
minute (RPM). There are two formulas that relate these
two values and take into consideration the tool bit
diameter.
SFM = .262 x Diameter (inches) x RPM
Slotting, routing shapes out of a sheet, periphery
routing, and cutting a part by machining around the
outside edge of the part, employ both conventional and
climb routing. Care should be taken in the machining
techniques and programs to allow for the desired finish.
Vibration
It is of the utmost importance that balance of the tool,
collet and spindle is maintained so that vibration is kept
to a minimum. Even small vibrations can introduce
stress that will eventually result in crazing and fractures
in acrylic sheet during fabrication or use. The maintenance of spindles and collets is a key factor in controlling vibration. The spindle and collet must be thoroughly
cleaned every time there is a bit change.
Operation Terminology and Formulas

Cutting Edge - The leading edge of the cutter tooth.
Flute - The space between the back of one tooth and
the face of the following tooth.
Axis - The imaginary straight line that forms the longitudinal center line of the cutter.
Helix Angle - The angle that is formed as the cutting
edge spirals around the outside of the tool. It is measured relative to the axis of the tool.
Shank - The portion of the cutter that is held in the
spindle in order to drive the tool.
Diameter Equals the largest outside cylindrical
dimension of the cutting tool, measured at the cutting
RPM = 3.82 x SFM / Diameter (inches)

For most operations the RPM commonly runs between
10,000 to 20,000. Depending on bit diameter, the speed
can be as low as 300 SFM and may run as high as 2400
SFM although it more commonly runs from 500 to 1500
SFM. This will change based on the demand for material
removal and edge finish requirement. This is the first of
three factors that will affect material finish.
Chip load - Inches Per Tooth (IPT) corresponds to the
amount of material removed by each tooth of the cutter
every time it contacts and passes the material. Sufficient chip load will create stability between the cutter
and the work piece. The optimum chip load for acrylic
sheet is .004" to .015"/tooth.
Feed Rate Inches per Minute (IPM) is the distance
that the cutting tool travels along the edge or surface of
the material being processed in one minute. The proper
range for feed rate can be determined by considering the
chip load. Operating in the lower part of the recommended range for chip load will tend to provide a better
finish but at the expense of throughput. Operating at the
high end of the recommended range for chip load will
result in a rough finish on the part but higher part
throughputs. Typical feed rate parameters for ACRYLITE
FF sheet range from 100 to 300 IPM. To establish the
feed rate knowing the desired chip load, the number of
cutting edges on the bit and the RPM use the following
formula:
IPM = IPT x No. Teeth x RPM
Trouble Shooting
Problem
Cause
Chipped Edges
Dull tool
Replace or sharpen tool
Spindle speed too slow
Increase speed (RPM)
Feed rate too fast
Reduce feed rate (IPM)
Vibration
Clamp securely
Rigidity
Check fixture clamping

Improper mounting
Cutter Damage
Improve storage and handling. Cutters should

not be thrown unprotected in drawers.
Total Indicator Run-Out (TIR)
Check tool and tool holder for run-out
Defective or worn collets
Replace
Bearing wear
Replace when tool run out exceeds .001-.002 inches
Rigidity
Check holder
Check machine for wear
Use shortest possible cutting tool
Chatter
Melted Edges
Solution
Spindle speed too high
Decrease spindle speed (RPM)
Chip load too high
Decrease feed (IPT)
Fixturing
Check for part movement
Dull tool
Replace or sharpen tool
Feed rate too low
Increase feed rate (IPM)
Spindle speed too high
Decrease speed (RPM)
Chip load too low
Increase feed (IPT)
No cooling
Add air or water mist cooling
Plastic melt or plastic

chips sticking to bit
Tool finish
Rough bit finishes allow material to adhere to cutting

edge. Use bit with polished flute.
Chip Packing
Too many flutes on bit
Make sure flute space is adequate

Use only one or two flutes for roughing
Plunge cutting
Use two flute up-spiral bit

Incorrect helix angle
Depth of cut too large
Make multiple passes
Exceed tool strength
Reduce feed rate

Reduce cutting edge length
Increase diameter of cutter
Reduce depth of cut
Rigidity
Check machine and part deflection

Ensure tool is fully engaged in chuck
Use the largest diameter bit
Use shorter bits
Cutter misaligned in collet
Correct cutter alignment
Defective or worn collets
Replace
Tool Breakage
Bearing wear
Replace when tool run out exceeds .001-.002 inches
Tool Burning
Dull tool
Sharpen or replace tool
Carbide Chipping
Loose collet
Tighten shank in collet
Deflection
Ensure shank is fully engaged in chuck

Use shorter cutting edge
Use larger diameter tool
Incorrect chip load
Increase number of flutes

Reduce feed rate
Excess heat
Increase chip load (reduce spindle speed or increase

feed rate)
Tool alloy
Use more wear resistant alloy (carbide)
Coolant
If coolant is used, it should be clean and high quality.

Use cold air gun or compressed air.
Causes of Premature
Wear

The suppliers listed below offer materials and equipment tested and approved by CYRO Industries.
Authorized ACRYLITE Sheet Distributors may also offer materials and equipment. Visit www.cyro.com
for a list of authorized CYRO sheet distributors.
Router Bits
Ekstrom, Carlson & Co.
5196 27th Avenue
P.O. Box 1611
Rockford, IL 61109
815-394-1744
Fax: 815-398-9439
www.ekstromcarlson.com
Great Lakes Carbide Tool Mfg., Inc.
101 N. Old Peshtigo Road
Peshtigo, WI 54157
715-582-3884
Fax: 715-582-4373
www.glct.com
Kennametal, Inc.
1600 Technology Way
Latrobe, PA 15650-0231
724-539-5000
800-446-7738
www.kennametal.com
Onsrud Cutter, Inc.
800 Liberty Drive
Liberty, IL 60048
800-234-1560
Fax: 800-557-6720
www.onsrud.com
Paso Robles Carbide, Inc.
731-C Paso Robles Street
Paso Robles, CA 93446
805-238-6144
Fax: 805-238-4263
Toolmasters LLC
1400 Railroad Avenue
PO Box 1611
Rockford, IL 61110
815-968-0961
Fax: 815-968-5559
www.toolmastersllc.com
Trend Lines, Inc.
100 Justin Drive
Chelsea, MA 02150
800-767-9999
Fax: 800-735-3825
www.trend-lines.com
Union Butterfield
P.O. Box 50000
Asheville, North Carolina 28813
800-222-8665
Fax: 800-432-9482
www.unionbutterfield.com
Wisconsin Knife Works
2505 Kennedy Drive
Beloit, WI 53511
800-225-5959
Fax: 800-336-1254
www.wkwinc.com
Woodworkers Supply
125 Jay Lane
Graham, NC 27253
800-645-9292
Fax: 800-853-WOOD
or 336-578-1401
www.woodworker.com
Continued on next page
Equipment and Materials Suppliers Continued from previous page
Collets and Tool Holders

Centaur Precision Tools Inc.
13098 SW 133 Court
Miami, FL 33186
888-COLLETS
Fax: 305-251-0756
www.centaurtools.com
REGO-FIX Tools
7752 Moller Rd.
Indianapolis, IN 46268
800-734-6349
Fax: 317-870-5955
www.rego-fix.com
Routers
Black & Decker Mfg. Co.
701 E. Joppa Road
Towson, MD 21287
410-716-3900
www.blackanddecker.com
C.R. Onsrud, Inc.
867 S. Main Street
Troutman, NC 28166
704-528-4528
Fax: 704-528-6170
www.cronsrud.com
Delta International
4290 E Raines Road
Memphis, TN 38118
800-223-7278
Fax: 800-535-6488
www.delta-portercable.com
KOMO Machine, Inc.

11 Industrial Blvd.
Sauk Rapids, MN 56379
800-255-5670
Fax: 320-656-2470
www.komo.com
MultiCam, Inc.
8920 North Royal Lane
Irving, TX 75063
972-929-4070
Fax: 972-929-4071
www.multicam.com
SB Power Tool Corp.
4300 W. Peterson
Chicago, IL 60646
888-394-4646
800-301-TALK
Fax: 800-547-1998
Shoda CNC Routers
www.shodausa.com
www.boschtools.com
Skil Tools
877-754-5999
www.skiltools.com
Thermwood Corp.
P.O. Box 436
Dale, IN 47523
800-533-6901
Fax: 812-937-2956
www.thermwood.com
Gerber Scientific Products, Inc.

151 Batson Drive
Manchester, CT 06040
800-222-7446
Fax: 860-645-5645
www.gspinc.com

and Assistance
on www.cyro.com.
of other facts about acrylics
from one of North Americas
sheet products.

379 Interpace Parkway,
PO Box 677, Parsippany, NJ 07054-0677
800-631-5384
www.cyro.com
www.degussa.com
CYRO Industries is a wholly-owned subsidiary of Degussa.
Fire Precautions
sufficient air will not be available and toxic carbon monoxide will be formed, as it will when other common combustible materials are burned. We urge good judgement
in the use of this versatile material and recommend that building codes be followed carefully to assure it is used properly.
Compatibility
may include cleaners, polishes, adhesives, sealants, gasketing or packaging materials, cutting emulsions, etc. See the Tech Briefs in this series for more information, or contact your ACRYLITE Sheet Distributor or the CYRO Technical Center for information on a specific product.
Important Notice
CYRO Industries, Parsippany, New Jersey 07054

10
1319(5F)-0302-5RA
Degussa, CYRO Industries, 379 Interpace Parkway, PO Box 677, Parsippany,

NJ 07054
800-631-5384
www.cyro.com www.degussa.com
Degussa, CYRO Industries, 379 Interpace Parkway, PO Box 677, Parsippany, NJ 07054
800-631-5384
www.cyro.com
www.degussa.com
TECH
BRIEF
Fabrication
#7 Line Bending
Equipment
Procedures
Trouble Shooting
Equipment Suppliers

& Assistance
The heating element is a 17-gauge nichrome (nickelchrome) wire. Attach the wire to a 120-volt, 20-amp
variable transformer. Provide a spring as shown to keep
the wire under tension. Allow space around the wire for
free air flow to aid heat transfer from the wire to the part.
Position the wire so it remains at least 1/8" from the
sheet during heating. Ceramic stand-offs are useful in
supporting the wire at a consistent height from the base
(see last page for source of supply).
CAUTION: An unguarded nichrome wire is a burn/
shock hazard. Provide a guard to prevent contact
with the wire.
Modification for Multiple Line Bends
Equipment
Straight Nichrome Resistance Wire Heater
To bend ACRYLITE FF acrylic sheet up to 1/8" (3mm)

thick, the most commonly used piece of equipment is
a straight nichrome wire resistance heater. The unit
functions similarly to a household electric toaster by
passing electricity through a wire.
You can bend material thicker than 1/8" (3mm) on this
unit, but the material must be flipped over halfway during
the heating cycle.
In constructing the heater, use plywood for the base.
The top surface should be insulation board or aluminum
sheet to provide a smooth surface, helping prevent
mark-off marks on the sheet as a result of contact.
Aluminum is selected as the metal alternative because
it is durable and does not absorb and re-radiate heat.
To perform multiple line bends, modify the heater as

shown above. Where the wire joins the spring, include
an insulation ring. Raise the units base so convection
air from below flows through slots routed in the base as
shown.
Coiled Resistance Wire

Coiled resistance wire can be substituted for straight
wire as a heating element. Because coiled wire must be
supported and because it is difficult to position the coils
evenly, temperatures across the sheets width may
vary, causing uneven stresses and distortion. See the
following section under Procedures entitled Line
Bending with Coiled Resistance Wire.
Tubular Rod Heaters

To heat sheet thicker
than 1/8" (3mm), use
a tubular-rod heater with
a heating rod like the
heating element of an
electric stove. Power
the heater with a
variable transformer.
Place a reflector,
preferably of split
aluminum conduit for
its good reflectivity,
beneath the rod. For shorter heating cycles, mount
heaters above and below the sheet. Use water-cooled
supports to avoid marks on the acrylic.
Procedures
Be sure to follow the manufacturers safety
recommendations for equipment and materials used
with ACRYLITE FF sheet.
Bending with a Straight Nichrome Wire Heater
Radiant Quartz Tube Heaters
Heat the material until it bends easily. Experience will

teach you how long to heat each part. Dont overheat or
lay ACRYLITE FF sheet directly on the heating element
- doing so will blister and/or mark the sheet.
Bend the heated part to the desired shape and quickly
place it in a cooling jig. To retain the bend while you do
other work, secure the part in the jig with weights or
clamps. Cooling time
normally equals
heating time.
Quartz tube heaters are among the most efficient
sources of radiant energy. They look like a thin
fluorescent light bulb. These units provide capability to
bend ACRYLITE FF sheet 1/4" (6mm) thick or greater.
The heater consists of a coiled resistance wire housed
in a quartz-coated glass tube.
Use a reflector with a quartz tube heater for most
efficient heating. For short heating cycles, mount
heaters above and below the sheet. Power the
heater(s) with a variable transformer.
Cooling Jigs
Use a cooling jig like
the one shown at left
to assure that your
bend is at the proper
angle and to prevent
the piece from
springing back into its
original shape. This is
an all-purpose jig for
90 bends - you can
modify it to suit the
part. A cooling jig
which exposes both
sides of the heated
sheet to air will accelerate cooling and reduce stresses.
2
When line bending

with only one heating
element, be sure to
bend away from the
heated side. For
example, if the
nichrome wire is on the
bottom, bend upwards.
Line Bending with Coiled Resistance Wire

Follow the procedures above for nichrome resistance
wire line bending. Flip the piece over while heating to
prevent uneven stresses in the bend area.
Long Line Bends

When a bend line exceeds 24 inches in length, there is
a tendency for the part to bow across the bend. This can
also happen when a bend is made close to the edge of
a sheet. To minimize bowing, restrict the width of the
heated area or, v-groove the sheet along the desired
bend line, as shown at right. When a line bend exceeds
36" in length, the part tends to bend unevenly (slight
wave) along the bend due to shrinkage. To minimize this
tendency, make the bend perpendicular to the manufacturing direction. You can tell manufacturing direction
when the label or masking paper is still attached to the
sheet. If there is a label, manufacturing direction is from
top to bottom as you read it. If masking paper is still on

the sheet, manufacturing direction is from top to bottom
as you read the words on the masking.
Trouble Shooting
Problem
Cause
Solution
Bubbling
or Blistering
Overheating
Lower heat;
Reverse or turn
over work.
Increase sheetheater distance
Pre-dry sheet
Wet material
Wrinkling
Narrow heating
Bending part
the wrong way
Mark-off
Surface contact
(stray marks
on sheet
surface)
Avoid overheating
Cover jig with felt
Reduce areas of
contact in
cooling jig
Bow Effect
Use straight
nichrome wire
to decrease
width of heated
area
Design reverse
curve in
cooling jig
Stresses from
heated and
unheated
areas
Sharp Line Bends

For sharp line bends
with no deflection, it is
a good idea to v-groove
the sheet, as shown at
left. Use a v-rabbet
router bit or a table saw,
making two opposed
45 cuts. V-grooving the
sheet reduces the
material cross section
at the point of bending,
reducing stresses and
making bending easier. A wire heater beneath the cut
will help create a sharp angle bend without deflections
or bowing.
Bending with a Tubular Heater

Bend the part as outlined above for a nichrome wire
heater. The ACRYLITE FF sheet should be at least half
an inch from the rod to avoid overheating.
Bending with Quartz Tube Heaters

Bend the part as outlined above for a nichrome wire
heater. The ACRYLITE FF sheet should be at least a
half inch from the tube to avoid overheating.
Gentle Bending
By changing the distance between supports, the worker
can increase or decrease the width of the heated area,
thus varying the curvature of the bend. In this way, the
part can be bent with a gentle curve instead of a rightangle bend.
Widen heated area

Increase bend
radius (bend
radius at least
twice sheet
thickness)
Bend away
from heated side
Heat entire
part in oven
Use a v-groove
bend line
Inherent
shrinkage
in sheet
Bend sheet
perpendicular
to direction of
manufacture see foregoing
drawing

The suppliers listed below offer materials and equipment
suitable for use with ACRYLITE FF sheet. Authorized
ACRYLITE Sheet Distributors may also offer materials
and equipment.
Variable Transformers
Superior Electric Company
383 Middle Street
Bristol, CT 06010
860-585-4500
Fax: 860-589-2136
www.superiorelectric.com
Staco Energy Products
301 Gaddis Blvd.
Dayton, OH 45403
937-253-1191
Fax: 937-253-1723
www.stacoenergy.com
3
Nichrom Wire/Strip Heaters

Pelican Wire Company
6266 Taylor Road
Naples, FL 34109-1896
941-597-8555
Fax: 941-597-9783
www.pelicanwire.com
Ceramic Stand-offs
CHROMALOX
Edwin L. Wiegand Division
Emerson Electric Co.
103 Gamma Drive Extension
Pittsburgh, PA 15238
412-967-3800
Fax: 412-967-5148
www.chromalox.com
Equipment
Edge Finisher Corporation
16 Stony Hill Road
Bethel, CT 06801
203-796-7923
Fax: 203-796-7924
www.edgefinisher.com
FTM, Inc.
6160 Cobblestone Road
Placerville, CA 95667
530-626-1986
Fax: 530-642-2602
www.thefabricatorssouce.com
C.R. Clarke & Company
4407 Vineland Road - Suite D5
3
Orlando,
FL 32811
800-676-7133
www.crclarke.co.uk

and Assistance
on www.cyro.com.
Sales Offices
call 800-631-5384, visit www.cyro.com, or contact
the nearest regional sales office.
Eastern Region
100 Enterpise Drive
PO Box 5055
Rockaway, NJ 07866
973-442-6130
Western Region
3180 Crow Canyon Place
Suite 240
San Ramon, CA 94583
925-866-9300
South/Central Region
101 East Park Blvd.
Suite 1039
Plano, TX 75074
972-424-6830
CYRO Canada Inc.

6285 Northam Drive
Suite 100
Mississauga,
Ontario L4V 1X5
905-677-1388
800-268-4743
Fire Precautions
Compatibility
Important Notice:
cyro.com
4
1319(7F)-0901-5RA
2001 CYRO Industries. All Rights Reserved. Printed in USA.

PO Box 677
800-631-5384
www.cyro.com
www.degussa.com

PO Box 677, Parsippany, NJ 07054
800-631-5384
www.cyro.com
www.degussa.com
Degussa, CYRO Industries, 379 Interpace Parkway, PO Box 677, Parsippany, NJ

07054
800-631-5384
TECH
BRIEF
Fabrication
#10 Thermoforming
Shop cleanliness is an important factor determining
Material Properties
the quality of the parts obtained. It is vital that the

thermoforming area is kept clean at all times. Dust
Cell cast acrylic sheet, such as ACRYLITE GP acrylic

sheet, has a high molecular weight while continuously
manufactured sheet, such as ACRYLITE FF acrylic
sheet, has a much lower molecular weight in comparison. Higher molecular weight acrylic has better heat
strength during forming but is more difficult to form due
to its higher melt strength and elastic memory. Lower
molecular weight acrylic forms more easily and with
great detail but is more sensitive to differential heating.
and other particles will greatly affect surface quality

of the finished product.
What is Thermoforming?
Thermoforming refers to the process of heating and
shaping a plastic sheet on a mold. Thermoforming can
range in complexity from manual operations to highly
automated, large scale ones.
Why Thermoform?
Thermoforming offers processing advantages over
competitive processes such as blow molding and
injection molding. Relatively low forming pressures are
needed and large size can be economically fabricated.
Since the molds are exposed to relatively low forces,
they can be made of inexpensive materials. Mold
fabrication time is therefore very short, minimizing lead
times. Thermoforming is often selected for fabricating
prototype and display parts due to its low tooling costs.
However as part volumes increase, processes such as
injection molding become more economical. Below is a
chart that compares the cost of making a part using
pressure forming (one type of thermoforming) and
injection molding.
Pressure
Forming
Injection
Molding
Tool Cost ($)
5,000
37,500
Cost/500 ($ each)
16.66
78.07
Cost/5000 ($ each)
6.95
10.37
Cost/10,000 ($ each)
6.40
6.53
Cost/20,000 ($ each)
6.10
4.65
Part Design Considerations

In designing a part for thermoforming, several things
must be taken into consideration to ensure the successful forming. Certain materials might not be suitable for
some applications. However, slight modifications to part
design can make forming of some parts more feasible.
Tight tolerances can be met with the proper process and
tooling. However, tighter tolerances make the forming
process more expensive. Keep in mind that with
thermoforming, details can be obtained only on one side.
ACRYLITE sheet expands and contracts with changes
in temperature. Therefore a temperature must be specified with the required
tolerances.
Draft angles are important to incorporate when designing
a part. The draft angle is the degree of taper on the mold
sidewall which allows for easier removal from the mold.
A draft angle greater than 5 is recommended.
Radii can facilitate
forming to a large
degree. Radii in this
case refer to any
corners in the part.
Radii reduce draw
ratios, giving more
uniform wall thickness
and reducing the
molded-in-stress.
Draft Angle
1
The depth of draw (H/W), which is the ratio of the height of the formed part
to the width of the rim opening, can play a role in part design if the
availability of forming equipment is limited. For example, parts with small
depth of draws can be formed with simple processes such as vacuum or
pressure forming. Parts with larger depth of draws require multi-step
processes which allow for such deep draw.
Wall thickness of the formed part is a function of initial thickness, depth of
draw, type of mold, and the shape of the part. Prestretching the sheet prior
to forming yields more uniform wall thickness. The deeper the draw, the
thinner the sidewalls. Below is a figure illustrating the effects of changes
in depth of draw (H/D) on wall thickness.
Draw Ratio vs. Radius
Wall Thickness of Sheet Formed in Cylindrical Female Mold
Wall Thickness of Sheet Formed in Rectangular Male Mold
Wall Thickness of Sheet Formed in Cylindrical Male Mold
Wall Thickness of Sheet Formed in Rectangular Female Mold
Mold Design
Mold Materials
Molds for thermoforming can be made out of many
materials ranging from wood or plaster to aluminum or
steel. Material selection depends on the number of parts
to be formed and on pressure and temperature requirements. Another major factor influencing material selection is cost. Cost refers not only to material cost, but
also to costs associated with fabrication, maintenance,
storage, and other aspects of working with the material.
Wood, plaster, and plastics are usually used for prototype production molds. Molds for applications such as
signs, containers, and displays are usually made out of
these materials. They are inexpensive to build but are
not very durable. Aluminum and steel molds are used for
high volume production requiring long tool life. These
materials are relatively easy to fabricate and offer
excellent surface hardness and low wear.
Mold Surface
Surface finish on the mold affects the surface quality on
the formed part. Any scratches or marks on the mold
will appear on the part surface. It is therefore important
to ensure that the surface of the mold is smooth.
However, a highly polished mold surface is NOT recommended as air can easily be entrapped between the
sheet and the mold surface causing imperfections in
part surface. In some applications the mold surface can
be finished to incorporate a desired texture, which is in
turn imprinted on part surface.
Vacuum holes and slots
Inclusion of an adequate number of properly located and
designed vacuum holes is necessary to ensure that air
trapped between the sheet and mold can be evacuated.
Vacuum hole diameter should not exceed material
thickness. Small holes can cause incomplete forming as
longer time would be required to evacuate trapped air.
Large holes leave undesirable marks on part surface.
Vacuum holes should be relieved by back-drilling using a

1/4-3/8 bit to within 0.080-0.100 from the mold surface. This makes the
change in cross section
from the vacuum line to
the vacuum hole more
gradual giving better
vacuum. To the right is
a figure illustrating typical back-drilled vacuum holes.
Heating and Cooling

The temperature of the mold should be high enough to
prevent sudden cooling of the sheet as the mold comes
in contact with it, but cool enough to avoid excessive
shrinkage in the part and unnecessarily long production
cycles. Uneven temperatures in the mold can also
cause forming defects. Different heating elements can
be used within the mold along with a temperature control
system to keep the mold at the proper temperature.
Thermocouples are inexpensive and should be used
generously as they provide invaluable information about
the forming process.
Cooling lines are often used in the mold to accelerate
cooling once a part is formed. Cooling lines or channels
should be spaced about 1.5-3 apart and channel
diameter should be 0.375-0.625. Cooling lines should
be no more than 40 in length as the coolant gets
warmer and loses its cooling efficiency causing
differences in cooling rates at different locations. Water
is typically the coolant of choice but other coolants can
be used.
Other mold considerations

Compatible mold release agent can be used to assist in
removing the sheet from the mold. Incompatible release
agents can attack the sheet causing crazing. For more
information on mold release agents, refer to the materials and equipment suppliers section in the back.
Male vs. Female Mold

There are two main types of mold design; male and female. One thermoforming feature to remember when selecting
the type of mold to use is that details on only one side can be obtained. Another difference between the two designs
is that with a male mold, the bottom of the part usually has the thickest and most uniform wall thickness while the
rim has the thinnest walls. In female molds the rim has the thickest walls while the bottom has the thinnest. Below is
an illustration showing the difference.
Other considerations include cost, tolerances, and part design.
Vacuum and Pressure Systems
Pre-drying
It is necessary to have sufficient vacuum and/or air

pressure in forming operations to obtain good results.
Poor vacuum or air pressure can result in poor detail,
incomplete forming, forming failure, and poor surface
finish.
Pre-drying ACRYLIITE FF sheet is rarely necessary.

Cases and skids of ACRYLITE FF sheet arrive wrapped
in polyethylene that slows down moisture absorption.
Keep the sheet wrapped until used. To prevent blistering,
dry high-water content sheet in a forced circulation
drying or vacuum oven before heating. Drying time
depends on water content and material thickness.
Twenty-four hours at 176F (80C) dries most sheets.
Thermoforming operations require a vacuum draw as

close to 30in Hg as possible. A minimum vacuum of
28in Hg is recommended for most operations. It is
essential to ensure that the proper pump and surge tank
are selected and that design and sizing of the surge
tank and the connections are adequate. Some of the
most common oversights in vacuum system design
include 90 bends, long pipes, restrictive valves, and
flow constrictors. Each 90 elbow reduces vacuum by
30% and should be eliminated whenever possible. Long
pipes between pumps and molds can also cause
considerable vacuum loss.
Air pressure requirements depend on the size of the
pressure box and the type of forming operation used. In
all cases air should be very dry with a dew point of
40F [-40C] and should be oil free. Pressures of up to
200 psi can be used in pressure forming operation.
Typically air pressures do not exceed 50 psi. It is
important that air pressure be slowly and carefully
evacuated from the pressure box. Evacuated air can be
reused in subsequent operations or can be used for
cooling the surface of the formed part after passing it
through vortex tubes.
To reduce the length of the forming cycle, pre-dry the

sheet in a spare oven and transfer it directly into the
forming oven at 176F (80C) after the drying period.
Clamping
It is important to provide sufficient clamping of the sheet
during the forming process. Inadequate clamping can
cause the sheet to come out of the clamping frame
during forming causing incomplete forming or failure.
Different types of clamps can be used. Typically pneumatically operated clamps are used. Teeth or ridges can
be added to the edge of the clamp to obtain better grip.
The engagement of the sheet in the clamp should be at
least 1, however different clamping set ups may require
more engagement.
The clamping system used in thermoforming should be
heated. Cold clamps act as a heat sink and prevent the
edges from stretching, causing poor detail around the
edges or forming failure.
Thermoforming Conditions
Forming Temperature
Selecting the proper forming temperature within the range depends on desired level of detail. Parts with high details
should be formed at the higher temperatures within the range. Set temperature refers to the temperature at which the
part can be safely removed from the mold. It is important that the mold is heated to the recommended temperature.
Cold molds cause sudden cooling of the part which adds significant stress into the part. Hot molds slow down the
cooling process affecting productivity. The following table shows typical conditions used to thermoform ACRYLITE sheet.
Material
Forming Temp Range F [C]
Set Temperature F [C]
ACRYLITE FF sheet
290-320 [145-160]
185 [85]
190 [88]
ACRYLITE GP sheet
340-380 [170-195]
185 [85]
190 [88]
Forming Rate
The maximum forming rate of a sheet is limited to the
speed at which it will stretch without exceeding its
strength and fracturing. The minimum forming rate must
be fast enough to prevent the sheet from cooling
appreciably.
A highly pigmented sheet should be formed more slowly
than a colorless or transparent material.
Excessively fast forming rates will impart high stresses
and cause low craze resistance. To minimize stresses
use moderate forming rates and ensure a uniform
temperature distribution over the surface of the sheet
and across its thickness.
To achieve greater draws or increased definition higher
forming temperatures are needed. For a slow forming
operation it may be necessary to continue with infrared
heating while the part is being formed.
4
Recommended Mold Temp F [C]
Heating the Sheet

Heating the sheet correctly is arguably the most important part of the thermoforming process. It is important to
obtain sufficient and uniform heat while minimizing cost.
ACRYLITE FF sheet is more sensitive to uneven
heating than ACRYLITE GP sheet. This difference
becomes very evident in applications like free blowing,
where uneven heating of ACRYLITE FF sheet results in
uneven domes. Heating processes are never 100%
efficient which means more heat must be supplied to
heat the sheet. Heating process selection depends
largely on sheet thickness and application. Thin sheet
can be efficiently heated using radiant heat. Thick sheet
and sheet used for parts with high optical requirements
are better heated using air convection.
The following table summarizes the features of different heating methods.

Heat Source
Coiled nichrome wire
Initial Cost
Efficiency
Average Life (hrs)
Very inexpensive
Poor
1,500
Metal (cal) rod
Inexpensive
Fair
3,000
Hot air ovens
Moderate
Poor
N/A
Ceramic elements
Moderate
Good
10,000
High
High
Excellent
Outstanding
20,000
10,000
Quartz Tube:
Nichrome filament
Tungsten filament
Forced convection hot air heating

This method is usually used for heavier gauge sheet as well as in applications with very high optical requirements
such as aircraft windshields. If the sheet is to be heated vertically, sufficient clamping pressures should be used to
prevent sheet slippage from the clamp as the material softens. Vertical heating generally is not recommended for
continuously manufactured or extruded sheet because the sheet could fall out of the clamps as it softens. Cell cast
sheet has sufficient melt strength to prevent it from falling out of the clamps. If the sheet is to be heated horizontally,
the horizontal surface must be clean and free of defects, as any imperfection on the surface will appear on the final
part. A clean plate of glass covered with talk powder can be used a surface for horizontal heating.
Before heating with an air oven, be sure that:
Temperature can be controlled
thermostatically within 10F (5C)
between 140-350F.
As a general rule, a sheet should be heated in an air convection

oven for 1 minute per 0.010 of thickness. Below is a chart
outlining recommended heating times for different thicknesses.
Air velocities across the sheet range

between 200-1000 feet per minute (1-5 m/s).
Temperatures throughout the oven are
uniform.
The clamping system exerts constant,
uniform pressure on all sides as the sheet
becomes soft.
Infrared radiant heating

This heating method is used for thin and medium thickness sheet and is the most efficient heating method. When
designing a horizontal heating system, independently controlled zones can be set up to improve control and flexibility.
In such a setup heaters in the perimeter zones can be set to a higher output than those in the center zone. This will
ensure uniform heating of the sheet.
Infrared radiation refers to electromagnetic waves with a wavelength greater than 710 nm. The wavelength at which a
sheet absorbs the most energy varies depending on the material. Proper selection of heating elements and temperatures can be accomplished by matching the peaks in the infrared spectra of the heating elements with the low points
in the IR transmission curve of the sheet material. Below is a chart showing the infrared transmission for acrylic.
%
When heating ACRYLITE sheet, quartz heaters at

1200F [650C] are the most efficient. Other less
expensive elements can be used, however, the efficiency of such elements are usually below 10%. Resistance rods and heating wires are examples of inexpensive elements which oxidize and lose efficiency relatively quickly.
Heating times vary depending on sheet thickness and
type, distance to heating element, type of heating
element, efficiency of heating element, and desired
detail. The chart below shows typical heating times for
two-side quartz heating for different thicknesses of
ACRYLITE FF sheet (heater temperature 1200F
[650C], mean wavelength 3.2m).
Core Temperature
For successful forming the core temperature of the
sheet needs to reach the recommended forming temperature range. For thin sheet energy transmission from
the heating element to the sheet surface is the limiting
factor for heating efficiency and time. Since radiant
heaters transfer heat to sheet surface quickly and
efficiently, they are used for thin sheet.
For thicker sheet the limiting factor is the transfer of
heat from sheet surface to the sheet core. Using radiant
heaters for thicker sheet will supply excess heat to the
surface which does not transfer fast enough to the sheet
core. The sheet must be heated for a longer time which
usually causes the surface to blister. For that reason air
convection is the preferred method of heating for thicker
sheet.
Pattern Heating
The final thickness of a formed part can be controlled by
controlling the heating profile on the sheet. Heating
sections of the part that undergo excessive thinning to
lower temperatures reduces the thinning in that section.
Wire mesh cut to the desired shape and size is usually
used to screen heat and achieve the desired temperature profile.
Measuring temperature
Proper heating of the sheet is essential for successful
thermoforming. The temperature of the sheet should be
in the correct range but also uniform to achieve complete forming results. Thermocouples should be used to
monitor the temperature of heating elements or ovens as
they provide vital information about heating. Thermocouples should be calibrated and used in close to where
6
the sheet will be in order to get a good temperature

measurement.
A quick way to measure the temperature of the sheet is
using infrared temperature measuring devices, or
pyrometers. Pyrometers are easy to use but only give
an indication of the surface temperature, NOT the core
temperature. Pyrometers use the emissivity of the
material to measure temperature. Emissivity is the
energy emitted by a material compared with that emitted
by a black body and is wavelength dependant. Many
pyrometers require setting the emissivity prior to measurement in order to obtain more accurate temperatures
of different surfaces. For acrylic an emissivity of 0.900.95 should be used. Note that the emissivity of mold
material can be considerably different. Using a pyrometer set to the emissivity of acrylic to measure mold
temperature will generate misleading results.
Temperature tapes are another great tool for determining
sheet temperature but are not as practical as pyrometers. Temperature tapes are thin adhesive backed tapes
that can be adhered to the surface of the sheet to
determine sheet temperature at that location. Temperature tapes are made to cover different ranges of temperatures so be sure the right tapes are used. Keep in
mind that temperature tapes leave marks at the location
where they are placed. Temperature tapes are ideal for
mapping the temperature of infrared heaters especially
at the beginning of a job. A scrap sheet with temperature
tapes adhered to different locations on the sheet can be
used for this purpose. The sheet can then be inserted
into the heating section and heated for the desired time.
When the sheet is removed, the temperature tapes will
give an indication of the temperatures reached at the
different locations. This information can be used to
adjust heater output in the different zones to obtain more
uniform heating.
Methods of Forming
Stretch forming
This is the simplest thermoforming technique. The
heated sheet is stretched into shape on the mold
surface. As the sheet touches the mold surface it cools
down causing that part to stop drawing. Since most
stretch forming operations dont involve a lot of stretching, wall thickness of the final part is relatively uniform.
To deter mark-off, cover the molds with rubberized
flocking or billiard table felt. Setting mold temperature
high and forming temperature low can help minimize
mark off on the part. Cover the part while on the mold so
the cooling rate is the same on both sides of the part.
Thick cloth or felt blankets make good covers.
Stretch Forming
Drape Forming
In this process a heated sheet is clamped in heated mold clamps and is stretched over a male mold by
lowering the sheet into the mold or by raising the mold into the sheet. The part of the sheet that touches
the mold first cools first and therefore ceases to stretch. That part of the sheet has the thickest wall.
Vacuum or air pressure is used to force the sheet against the mold. The sidewalls of the final part are
thinner than the top while the rim has the thinnest walls.
Drape Forming
Vacuum Forming
In vacuum forming heated clamps are used to clamp the hot rubbery sheet. The sheet edges are then sealed against
the rim of a female mold and vacuum is applied from the mold side. The edge is the first part to cool down and will be
the thickest. The sheet is drawn against the mold surface. The final part will have thin sidewalls and a very thin
bottom.
Vacuum Forming
Pressure Forming
This process is similar to vacuum forming except that positive air pressure from a pressure box, not vacuum, is used
to force the sheet against the female mold. Typically pressures no greater than 50 psi is used for pressure forming.
However pressures up to 200 psi are sometimes used.
Pressure Forming
Free blowing and vacuum drawing

Many configurations can be free formed using a shaped
clamping ring or vacuum-drawn using a vacuum box.
Items with very high optical quality can be produced by
these methods because the surface of the material
never touches the mold walls. Thus no mark-off or local
cooling occurs.
cooling. Installing baffles or screens in front of the inlet

opening can deflect the incoming air.
The pressure or vacuum is varied to get the desired

height or depth. The height is demarcated with a jig or
soft material designed to avoid marking. Pressure or
vacuum can also be controlled automatically with optical
light sensors. Although this method is more expensive,
its lack of contact creates an advantage in opticalcritical production.
Vacuum Drawing
Resting the sheet blank on a cold base plate may cause

undesired cooling while installing the clamping frame. To
reduce this heat the plate or cover it with thick, nonlinting cloth.
Free Blowing
A simple suction or blowing mold consists of a base

plate with a clamping frame. Enough mechanical or
hydraulic toggle clamps must be provided to maintain
frame rigidity and to withstand the forming pressure.
Using screw clamps has the disadvantage of being time
consuming and may allow the sheet to cool excessively
before it is formed. Beaded clamping frames will seal
better than flat frames.
For free blowing use up to 75 psi of air pressure. Provide
large air connections so that large parts can be shaped
quickly, but be sure that the incoming compressed air
does not hit the hot panels directly and cause local
Vacuum forming requires the same fundamental conditions as pressure forming except less clamping force is
needed because suction seals the sheet to the vacuum
box automatically and the pressure difference is limited
to 15 psi or less. If possible arrange the suction ducts in
a ring around the edge of the vacuum box to prevent
airflow from cooling only one side of the part. For
processing large parts, fit a reservoir (or vacuum tank)
in front of the vacuum pump for quick evacuation of
large volumes of air.
Multiple Step Forming methods
One step forming is usually used for thin gauge sheet
since it is rather easy to form. Thicker gauge sheet is
sometimes more difficult to form using one-step methods due to limitations with wall thickness uniformity.
Multiple step forming involves stretching the sheet either
using a plug assist or a billow and then forming the
sheet against the mold. Wall thicknesses obtained using
these methods are more uniform than those obtained
using single step methods.
In billow drape forming, a heated sheet is clamped in heated clamps and air is applied to expand the sheet as in
the case of free blowing. Air pressure used to form the billow is usually 18-22 psi. A male mold is then inserted
into the billow causing the sheet to take the form of the mold. Vacuum is sometimes applied from the mold side
to assist in forming the sheet against the mold surface.
Billow Drape Forming

8
Vacuum snap-back forming is very similar to billow

drape forming except the sheet is prestretched by
drawing it into a box using vacuum before the mold is
inserted into the prestretched sheet. At that point the
vacuum from the vacuum box is released and vacuum
is then applied from the mold side.
Shrinkage
ACRYLITE FF sheet shrinks slightly when heated to its
thermoforming temperature because of the orientation
imparted during manufacture. To find the manufacturing
direction look at the label or printed masking. As you
read a label manufacturing direction is from top to
bottom.
In fabrication operations not requiring heating, original
dimensions wont change. However sheet heated to
thermoforming temperature changes dimensionally.
Maximum shrinkage for ACRYLITE FF sheet is 3% in
the manufacturing direction and 0.5% in the transverse
direction (width increase). Shrinkage in ACRYLITE GP
sheet is about 1.5% in both dimensions.
Vacuum Snap-Back Forming
Billow vacuum forming is another multi-step forming

process. This method involves stretching the clamped
heated sheet away from the female mold using air and
then applying vacuum on the mold side to form the
sheet.
If ACRYLITE FF sheet is not held in a retaining frame,

measure the shrinkage of a scrap piece then determine
the size of material required to compensate for shrinkage before cutting any blanks.
In plug-assist forming the clamped, heated sheet is

prestretched using a mechanically driven plug into a
female mold. Vacuum is then applied from the mold side
to force the sheet against the mold surface. Plug assist
pressure forming is a variation of the plug assist
vacuum forming. Pressure is applied from the plug side
rather than vacuum from the mold side to force the
sheet onto the mold surface.
Some techniques utilize both plug assist and billows to
achieve excellent wall thickness uniformity. Such
processes include reverse draw with plug assist, in
which a clamped and heated sheet is stretched into a
billow and a plug is lowered to force the sheet into a
female mold cavity. Air pressure from the plug side is
then applied to force the sheet against the female mold
Cooling
After forming cool the part to below 140- 160F (6070C). Dont just cool the surface the interior must cool
too! Provide uniform cooling on all sides to prevent
stress. Completely cover slow-cooling, thick-walled
parts with felt or blankets to block drafts.
There is no rule of thumb for predicting the sheet
interiors cooling time. Factors include material thickness, ambient air temperature, and airflow to the part.
Experience is the best teacher. Fans are sometimes
used to accelerate the cooling process. Care must be
taken to avoid differential cooling of the sheet which
could result in poor surface finish, warping, and high
forming stresses. Some molds incorporate cooling lines
to assist in the cooling process. For more information
refer to Heating and Cooling under the Mold Design
section.
As the sheet cools it shrinks due to thermal expansion/
contraction. Shrinkage on the mold can cause stress so
it is best to remove the part as soon as it achieves
dimensional stability.
Sheet Manufacturing Direction
It is important to distinguish between shrinkage in the

material due to manufacturing process and due to the
forming process. In order to predict the latter, test trials
must be performed. This will assist in holding the right
tolerance. If part design does not include any details,
male molds can be used to hold tolerances as they
prevent the sheet from shrinking.
Trimming
Thermoformed parts often need to be trimmed before
usage in final applications. Certain thermoforming
machines have an in-line trimming station. Conventional
fabrication operations, such as saw cutting and routing,
can also be used. For more information on machining of
ACRYLITE sheet, please refer to the CYRO fabrication
briefs or visit the TechKnowlogy Center at
www.cyro.com.
Annealing
Thickness
The sheet undergoes various stresses during the

thermoforming process due to stretching, forming, and
temperature changes. The induced stress in the sheet
makes it more susceptible to chemical attacks. For
certain applications, such as those requiring sterilization
with alcohols and other incompatible chemicals, stress
in the sheet will cause the material to craze and crack
over time. One way to relieve forming stress is to anneal
the final part.
(in.)
Annealing is the process of heating the sheet to a high

enough temperature to allow for molecules to relax
without affecting the shape of the final part. ACRYLITE
sheet can be annealed at 175F [80C]. The following
table gives information on heating and cooling times.
Acknowledgement
Heating Time
Cooling Time*
(mm)
(hours)
(hours)
0.080
2.0
0.118
3.0
0.117
4.5
4.5
0.236
6.0
0.354
9.0
* Cooling rates of about 25F/hour are recommended
We would like to thank McConnell Co., Inc. Thermoforming

Consultants for the information and illustrations, as well as for
editing the contents of this technical brief.

Thermoformers
Infrared Heaters
Temperature Tapes
Mold Release Agents
Plastic Vac, Inc

214 Dalton Avenue
Box 5543
Charlotte, NC 38225
800-438-4139
Fax: 704-334-0251
www.pvi-plasticvac.com
Solar Products, Inc.

228 Wanaque Avenue
Prompton Lakes, NJ 07442
800-616-2601
Fax: 973-835-7856
www.solarproducts.com
Paper Thermometers
Paper Thermometer Co.
515 East Road
Greenfield, NH 03047
603-547-2034
Fax: 603-547-2073
www.paperthermometer.com
Miller-Stephenson
P.O. Box 950
Danbury, CT 06813-9982
800-992-2424
Fax: 203-791-8702
www.miller-stephenson.com
Brown Machine LLC

330 North Ross Street
P.O. Box 434
Beaverton, MI 48612
989-435-7741
Fax: 989-435-2821
www.brown-machine.com
Zed Industries, Inc.
3580 Lightner Road
P.O. Box 458
Vandalia, OH 45377
937-667-8407
Fax: 937-667-3340
www.zedindustries.com
Ovens
Despatch Industries
63 St. Anthony Parkway
P.O. Box 1320
Minneapolis, MN 55418
800-860-3944
Fax: 612-781-5454
www.despatch.com
The Grieve Corporation
500 Hart Road
Round Lake, IL 60073
847-546-8225
Fax: 847-546-9210
www.grievecorp.com
10
Fostoria Industries, Inc.

1200 N Main Street
P.O. Box 986
Fostoria, OH 44830-0986
800-495-4525
Fax: 419-435-0842
www.fostoriaindustries.com
Trent, Inc.
201 Leverington Avenue
Philadelphia, PA 19127
215-482-5000
Fax: 215-482-9389
www.trentheat.com
MAAC Machine, Inc.
590 Tower Blvd.
Carol Stream, IL 60188
800-588-MAAC
Fax: 630-665-7799
www.maacmachinery.com
American Catalytic
Technologies
209 Montowese Street
Branford, CT 06405
800-648-1698
Fax: 203-483-6693
www.americancatalytic.com
Celsistrip
Solder Absorbing Technology
144 Oakland Street
Springfield, MA 01108
800-628-8862
Fax: 413-788-0490
www.spirig.com
Infrared Thermometers
Raytek Corporation
Portable Products Division
1201 Shaffer Road,
P.O. Box 1820
Santa Cruz, CA 95061-1820
800-866-5478
Fax: 831-425-4561
www.raytek.com
UEI
8030 SW Nimbus
Beaverton, OR 97008
503-644-8723
Fax: 503-643-6322
www.ueitest.com
Other release agents can be

used. A sample of the
release agent should be sent
to the technical center for
compatibility testing.
Forming Supplies
Sueded Neoprene Rubber
Suede-O-Prene
Ohio Flock-Cote Company
7200 Northfield Road
Cleveland, OH 44146
440-439-1480
Fax: 440-439-7413
Seminars
McConnell Co., Inc.
Thermoforming Consultants
3030 Sandage Avenue
Fort Worth, TX 76110
817-926-8287
Fax: 817-926-8298
www.thermoforming.com
Trouble Shooting
Problem
Cause
Solution
Uneven shapes
Uneven heating temperatures
Be sure all heaters are functioning

Eliminate drafts
Baffle heat on all sides
Preheat clamping frame
Preheat entire sheet
Lower temperatures
Increase distance between heaters and sheet
Be sure all heaters are functioning
Use screening to balance heat
Pre-dry
Preheat
Keep masking on sheet until formed
Lower the heater temperature
Use older material first
Heat sheet longer
Raise heater temperature
If problem occurs in same area every time,
check if all heaters are functioning
Heat frame to recommended temperature
Check if vacuum/pressure at mold is sufficient
Remove 90 bends from vacuum system
Check vacuum holes for clogging
Increase number of vacuum holes
Check vacuum system design
Back relieve vacuum holes
Use vacuum slots instead of holes
Reduce heating time
Increase heating distance
Reduce heater temperature
Check vacuum system
Add more vacuum holes
Redesign mold
Use female mold instead of male mold
Add blocks to base of mold
Increase draft angles and radii
Reduce heating time
Reduce heating time
Increase heating time
Increase heater temperature
Reduce closing speed
Lower mold temperature
Reduce heating time or temperature
Increase draft angle
Use female mold
Remove part from mold as soon as possible
Add more water channels to mold
Check for plugged water flow
Raise part temperature
Use proper mold covering (foam, felt, flocking)
Change mold material
Grit blast mold surface
Check vacuum system
Add vacuum holes
Reduce mold temperature
Increase mold temperature
Clean with deionizer air
Preheat clamping frame
Use slip clamp frame (low/high)
Heat frames to proper temperature before inserting sheet
Add supplemental heat to corners
Heat sheet evenly
Preheat frames or use heated frames
Add supplemental heat to corners
Clamping frame not hot

Blisters or Bubbles
Heating too rapidly

Uneven heating
Excess moisture
Poor Detail,
Incomplete Forming
Sheet too cold
Clamping frame not hot enough

Insufficient vacuum or pressure
Vacuum draw not fast enough
Webbing or Wrinkling Sheet is too hot
Insufficient vacuum
Draw ratio too large in some areas of the mold
Too much sag
Sheet is too hot
Tearing sheet
when forming
Sheet is too hot

Sheet is too cold
Closing speed between mold and sheet too high

Part Sticking to mold Mold or sheet temperature too high
Draft angle too small
Part Warpage
Uneven part cooling
Surface markings
Mold temperature too low

Mold surface too rough
Mold surface too smooth
Poor vacuum
Uneven edges
Mold is too hot

Mold is too cold
Dirt on sheet or mold
Excessive forming temperature differential
Raised corners
Excessive stress
Cracking in corners
Stress concentration
11
www.cyro.com
800 631 5384

and Assistance
on www.cyro.com.
of other facts about acrylics
from one of North Americas
sheet products.
Sales Offices
visit www.cyro.com, or call 800-631-5384.
Degussa
CYRO Industries
PO Box 677
Parsippany, NJ 07054-0677
Web site: www.cyro.com
Fire Precautions
sufficient air will not be available and toxic carbon monoxide will be formed, as it will when other common combustible materials are burned. We urge good judgement
in the use of this versatile material and recommend that building codes be followed carefully to assure it is used properly.
Compatibility
may include cleaners, polishes, adhesives, sealants, gasketing or packaging materials, cutting emulsions, etc. See the Tech Briefs in this series for more information, or contact your ACRYLITE Sheet Distributor or the CYRO Technical Center for information on a specific product.
Important Notice

12
1319(10E)-0603-10MG
Degussa, CYRO Industries, 379 Interpace Parkway, PO Box 677, Parsippany, NJ 07054
800-631-5384
For additional information contact:Degussa, CYRO

Industries
PO Box 677, Parsippany, NJ 07054
800-631-5384
www.cyro.com
www.degussa.com
Degussa, CYRO Industries, 379 Interpace Parkway, PO

Box 677, Parsippany, NJ 07054
800-631-5384
TECH
BRIEF
Fabrication
#13 Laser Machining
Procedures
Setting Up To Cut ACRYLITE FF Sheet
Equipment
Procedures
Trouble Shooting
Equipment Suppliers

and Assistance
Equipment
CO2 lasers, used in appropriate applications, are powerful and cost effective tools for cutting ACRYLITE FF
acrylic sheet. Small complex parts with clean, sharp
inside corners, and parts of any size which require
cutting tolerances of less than 0.005/ft. can be cut with
a laser and left with a polished edge finish. Because
laser-cutting offers a narrow kerf (0.010-0.020), tremendous shape and size capability, as well as a clean
polished, dust free cut, it is the premier choice for many
quality applications.
There are three basic variables involved when cutting

with a laser, each affecting the quality of the cut and the
resultant level of stress in the material being cut: the
power of the laser, the feed rate, and the pulse rate.
These can all be adjusted to allow for different material,
material thicknesses and edge finishes. To cut
ACRYLITE FF sheet, a laser as small as 40 watts can
be used for thicknesses up to approximately . To get
good edge quality with a small laser, however, you must
slow the feed rate to approximately 20 inches/minute.
For thicker sheet or faster feed rates, a larger laser is
needed. A 180-watt laser will provide fast economical
cutting of most thicknesses of acrylic sheet using only
about 75% power. Laser machines with higher wattage,
500 to 1000 watts, permit higher feed rates and cutting
with multiple heads at one time.
The Design of a CO2 Laser

CO2 lasers work by emitting a beam of parallel light that
has a wavelength of 10.6 micron. This wavelength of
light is absorbed well by non-metals. When the beam of
light or energy is focused through a lens to a very small
point, it vaporizes the material in its path. This focused
laser beam can be held stationary over an xy-axes
positioning table or it can be positioned over a stationary
surface using a flying head configuration. A flying head
set-up means that the laser beam moves over the work
on one or two axes through the use of mirrors and
mechanical positioning equipment. The controllers, PCs
and software used to control the positioning of the laser
and the work are very similar to the hardware and
software used with other CNC machining equipment.
This makes designing for and using the laser cutter no
more difficult than working with any other CNC machine.
Data taken from Laser Processing of Plastic Sheet by Tim

Christopherson, Plastics Fabricating & Forming, September/
October 2000.
1
Trouble Shooting
Increasing the power of the laser at a given feed rate
usually will result in a more glossy finish, but it also
increases the level of stress in the edge of the sheet.
A faster feed rate with a more rapid pulse rate will
generally result in an edge with lower stress but a less
glossy surface.
The pulse rate of a laser (measured in pulses per
second pps) is the rate at which a laser fires. The
beam of the laser is actually a series of small bursts or
pulses, not a continuous stream. The pulse rate can be
controlled in two ways: proportionally to time or proportionally to distance traveled. While the pulse rate
proportional to time method is more common and easier
to program initially, this method usually results in burned
inside corners. The xy-controller takes longer to make a
corner than a straight line so the corners (particularly the
inside corners) absorb too much energy and tend to melt
and become over-stressed. This is an important consideration when cutting notch sensitive materials like
acrylic and polycarbonate. Inside corners are always
weak, high load areas. Everything possible should be
done to reduce stress or notches in these areas. Making the pulse rate proportional to the distance traveled
eliminates much of this problem. As the controller slows
the feed rate at the corners, the pulse rate slows down,
keeping constant the amount of energy emitted at a
given point on the cut.
Important Considerations When Cutting

ACRYLITE FF Sheet
No matter how sophisticated the controller or how fast
the feed rate, edge stress will always be a consideration
in certain applications. Any time a sheet of acrylic or
polycarbonate is heated, the possibility of heat stress
exists. This problem is greatest when only part of the
sheet is heated, which is the case with laser cutting.
The interface on the non-heated body of the sheet and
the rapidly heated, rapidly cooled edge of the laser cut
sheet is susceptible to crazing. These highly stressed
areas extend approximately 0.010-0.050 (depending on
thickness) into the sheet. They are very susceptible to
crazing from contact with incompatible solvents or from
high mechanical stress, for instance, due to bending.
Adjusting the feed rate, pulse rate, and power can
minimize the edge stress problem. Lower power and a
slow pulse rate, combined with a relatively rapid feed
rate, reduces the amount of energy or heat which is
absorbed by the sheet. Thereby, reducing both the
amount of stress and the distance that the stress
extends into the sheet. These conditions, however, will
result in a less glossy edge finish. In some circumstances, it may be practical to scrape or machine away
the stressed areas.
Gas Assist And Vacuum Table

Most high-powered lasers come equipped with a vacuum
hold-down table and a gas assist stream. The type of
gas used, the flow rate of the gas assist stream, as well
as the efficiency of the vacuum table in removing
vapors can influence the quality of the laser cut that is
achieved. Good gas flow across the laser cut combined
with an effective vacuum will help to remove vapors
which can damage the work piece, result in small flames
and charring, or leave behind unwanted residues.
Laser Cuttable Masking

Masking performance is an important consideration
when selecting acrylic sheet for your application. If
masking does not adhere well, parts can be damaged
or scratched during fabrication and the efficiency of the
fabrication process itself can be reduced. At other
times, masking can be difficult to remove resulting in
extra labor and cost. The proper choice of masking for
each type of fabrication process can help to minimize
problems.
Traditionally, paper masking has been the masking of
choice for laser cutting. It will not fuse to the acrylic at
the edges of the laser cut sheet. Its strong consistent
adhesion will prevent the masking from lifting while
handling and laser cutting, protecting the acrylic sheets
surface from the hot, corrosive gases generated by the
laser. Laser cuttable polyethylene masking is now
available on acrylic sheet.
For maximum laser cutting efficiency and output, a
specially formulated light adhesive polyethylene masking can be used. This masking removes very easily
from a laser cut part, yet offers sufficient adhesion to
withstand most ordinary handling. Although it is rarely a
problem, this type of masking may lift in areas where
the laser is prone to idle for excess periods of time due
to the maskings light adhesive formula. This can occur
at the beginning of a laser cut or when making a very
tight radius cut. Lifting is easily prevented by using a
lead in at the beginning of the laser cut and by reducing
the pulse rate or power when tight radius bends are
negotiated.
For a pristine, polished edge, a specially formulated nonadhesive polyethylene masking is available. Because
all adhesive-based maskings will leave some residue on
a laser cut edge, they can slightly reduce the polished
appearance of the laser cut edge. For applications
demanding the very highest appearance polished edge,
a non-adhesive laser cuttable masking is recommended. This type of masking may be a little more
difficult to remove from the laser cut part than an
adhesive based masking, but will provide a slightly
higher quality polished edge. It is also slightly more
resistant to edge lift. If lift does occur, similar steps can
be taken as those described above.
Another consideration with regards to masking is
wrinkles. In order to retain the original optics of the
sheet being cut, the masking, particularly the masking
on the top of the piece, must be wrinkle-free. If the
masking is not in contact with the sheet at the point of
the cut, the hot laser gases will be trapped between the
masking and the sheet, etching the surface. Etching is
often not a problem on the bottom of the sheet because
most xy-tables use a vacuum hold down system. The
vacuum effectively removes the hot gases from the
bottom of the sheet before they can cause any damage.
Maintenance
Like all sophisticated equipment, laser cutters require
regular maintenance for optimum performance. It is a
good practice to note the power setting required to cut a
given thickness of material at a specific cutting speed.
Over time, the power setting must be raised or cutting
speeds reduced, due to the laser optics becoming dirty
and out of focus. As this occurs cut quality will also
degrade. Regular maintenance by a qualified technician
will help maintain cutting efficiency and quality.
Safety
While lasers are high-powered sophisticated tools, they
are no more or less dangerous than any other piece of
shop equipment when properly installed and operated.
Standard safety glasses are often all that is necessary
for eye protection. However, not all standard safety
glass is opaque to 10.6-micron light (i.e., optical density
of 5 at 10,600 nanometers), common to some lasers.
ANSI Standard Z136.1 states that safety eyewear must
be labeled with the wavelength and optical density
protection factor. An exhaust system is needed to
remove the potentially harmful vapors produced when
the material is cut. Depending on the material cut, it may
be necessary to filter the vapors before exhausting them
outside. As with any other piece of equipment, proper
knowledge of operating and safety procedures is necessary before using a laser cutting system.
Emissions
A number of scientific investigations have been performed by various researchers to determine the amount
and type of emissions that result from laser cutting
acrylic. Despite these efforts, it is impossible to predict
the exact by-products and their concentrations in the
emission gases generated by laser cutting acrylic.
These depend upon the laser parameters, processing

parameters, cover gases, exhaust method, and exact
composition of the acrylic polymer. Additionally, these
studies do not include the effects of the protective paper
or polyethylene masking provided on acrylic sheet, nor
do they include the possible impact of coatings.
When laser cutting acrylic, most of the decomposed
acrylic is converted into its constituent monomers. In
typical ACRYLITE acrylic sheet, these monomers
include over 90% methylmethacrylate and the remainder, methacrylate. Many suppliers of acrylic also
employ ethylacrylate in their acrylic formulations.
(Ethylacrylate is included by the National Toxicity
Program in its list of substances that may be anticipated
to be carcinogens. The International Agency for Research on Cancer lists ethyl acrylate as a probable
carcinogen.)
During independent scientific research, Heferkamp,
Goede, Engel, and Wittbecker found that of the plastics
they tested, acrylic resulted in the lowest aerosol
generation (<10 mg/m3). Their work also indicated that
over 90% of the emissions from laser cutting acrylic
were gaseous methylmethacrylate monomer.
Troughton, Sims, Ellwood and Taylor found, in addition
to methylmethacrylate monomer, small amounts of
toluene, methy-2-methyl-3-pentenoate, xylene, trimethyl
benzene and alkanes. They found no PAHs which was
contrary to the earlier findings of Ball, Kulik and Tan.
For more information see the references listed
below. CYRO Industries recommends installing adequate ventilation equipment to ensure employee
exposures are below regulated levels. Consideration
should be given to environmental regulations if exhausting the gases outside. Manufacturers of laser cutting
equipment can provide guidance on the collection and
handling of laser emissions.
Sources
H. Haferkamp, M. Goede, K. Engel and J. S. Wittbecker,
Hazardous Emissions: Characterization of CO2 Laser
Material Processing, Journal of Laser Applications,
1995, 83-88, 7.
John M. Kokosa, Hazardous Chemicals Produced by
Laser Materials Processing, Journal of Laser Applications, 1994, 195-201, 6.
Mike Troughton, Jake Sims, Peter Ellwood and Helen
Taylor, Fume Emissions From Laser Cutting and Hot
Gas Welding of Plastics.
Cutting Without Emission, Industrial Laser Review,
Sept. 1995, 159.
CYRO Industries

The suppliers listed below offer materials and equipment
suitable for use with ACRYLITE FF sheet. Authorized
ACRYLITE Sheet Distributors may also offer materials
and equipment.
For more information or specific questions about

your project, contact your Authorized Distributor,
call 800-631-5384 or visit: www.cyro.com
Laser Machining, Inc.

500 Laser Drive
Somerset, WI 54025
715-247-3285
Fax: 715-247-5650
www.lasermachining.com
TSI Lumonics Corp.
8401 Jefferson Hwy.
Maple Grove, MN 55369
763-315-1780
Fax: 763-315-1781
www.tsilumonics.com
Universal Laser Systems, Inc.
16008 N. 81st Street
Scottsdale, AZ 85260
480-483-1214
Fax: 480-483-5620
www.ulsinc.com

and Assistance
on www.cyro.com.
Curbell Plastics is a proud supplier of Acrylite materials

Nationwide
1.888.CURBELL
www.curbellplastics.com
Fire Precautions
Compatibility
Important Notice:

4
1319(13)-1101-5RA

Acrylite Fabrication Guide

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TECH

If ACRYLITE FF sheet is stored horizontally, it must not

Curbell Plastics is a proud supplier of Acrylite materials

You can remove paper masking with a cardboard tube

Caring for ACRYLITE FF Sheet

Neutralizing Static Electricity

Roll the masking paper back enough to allow work

To temporarily eliminate the electrical charge on all

Contact your local Authorized Distributor of ACRYLITE

Fine scratches can be removed by hand polishing. Apply

Equipment and Materials Suppliers

Anti-Static Cleaners and Polishes

Anit-Static Air Guns

210 and 210 Plus

Plexus Plastic Center

Additional Technical Information and Assistance

Degussa, CYRO Industries

2. When selecting a panel saw, also be sure that it

This brief gives advice for:

Additional Technical Information

3. A solid hold-down system that clamps the material

If using a table saw, be sure it comes equipped with all

With any saw, blade alignment is critical for achieving

The optimum number of teeth per blade can vary

There are several saw blades on the market that can

10 diameter, 60 and 80 tooth

10 diameter blade rotating at

The 10 blade size is suitable because the SFM is

Run-out (or wobble) of the saw arbor and blade collar

* Table saws or beam type panel saws only.

For gang cutting of stacked sheets, a saw blade whose

For cutting acrylic, the teeth of the saw blade should

The quality of construction of the saw blade significantly

Best results are achieved when the teeth have a

Grinding quality or surface finish of the teeth, which

Feed the material evenly through the saw. Uneven feed

Saw Blade Dampeners/Stiffeners

When cutting on a table saw, care must be taken to

Ensure all guards are in place and operational.

Never position your body directly behind the saw

Chipping at bottom of cut:

Defective teeth (broken or out of alignment)

Equipment and Materials Suppliers

Equipment and Materials Suppliers

Oakite Fisan LC55

Additional Technical Information and Assistance

Degussa / CYRO Industries

Additional Technical Information

1. Tip angles on standard drill bits are commonly

2. The cutting edge must be ground flat to a 0-4 rake

The helix angle on a bit is the angle between the cutting

3. The surface behind the cutting edge must be ground

Bit geometry affects the quality of drilled holes since it

When drilling ACRYLITE sheet, heat is generated due to

Suggested Drilling Conditions

Table 1: Recommended values for SFM and IPR

Figure 1: Spindle Speed recommendations (RPM) for drilling acylic (D=0.063"-0.375")

Figure 2: Spindle Speed recommendations (RPM) for drilling acylic (D=0.380"-1")

Figure 3: Feed rate (IPM) recommendations for drilling acrylic

As indicated in the graphs and table above, lower SFMs

It is difficult to precisely control feed rate in manual

The shape of chips generated from drilling can serve as

Deburring and Countersinking

Air or liquid coolants should be used whenever possible.