Cast vs. Extruded Acrylic: Understanding the Differences

When working on laser cutting and engraving projects, choosing the right type of acrylic is crucial for achieving the desired results. At Houston Acrylic, we primarily offer cast acrylic sheets, with the exception of our mirror and iridescent options. 

Cast Acrylic: The Premium Choice

Cast acrylic is produced through a meticulous casting process, where liquid acrylic is poured into a mold and allowed to solidify. This method results in a high-quality product that is ideal for a variety of applications.

Advantages of Cast Acrylic:

1. Engraving Excellence:

   • Cast acrylic is known for its superior clarity, making it ideal for engraving. The material allows for precise and intricate engraving, perfect for artistic projects, signage, and personalized items.

2. Lesser Odor:

   • During laser cutting or engraving, cast acrylic emits a milder smell compared to extruded acrylic. This makes for a more pleasant working environment, especially during extended projects.

3. UV Resistance:

   • Cast acrylic is inherently resistant to UV radiation, ensuring that it won’t yellow or degrade when exposed to sunlight. This makes it a great choice for outdoor applications, architectural features, and window panels.

Extruded Acrylic: An Overview

Extruded acrylic, on the other hand, is produced by forcing molten acrylic resin through a die to create a continuous sheet. While it differs from cast acrylic, extruded acrylic has its own advantages.

Advantages of Extruded Acrylic:

1. Cutting Ease:

   • Extruded acrylic is easier to cut, responding well to laser cutting processes. It’s ideal for applications where efficient and precise cutting is a priority, such as in signage and architectural models.

2. Tolerance in Thickness and Sizing:

   • Extruded acrylic generally has a narrower tolerance in thickness and sizing, offering greater uniformity across the sheet. This makes it suitable for projects that demand consistency, like glazing panels and protective barriers.

Choosing the Right Acrylic for Your Project

When deciding between cast and extruded acrylic, consider the specific needs of your project:

• Cast Acrylic is the optimal choice if you prioritize superior engraving results, a milder odor, and the ability to work with varying thicknesses.
• Extruded Acrylic might be more suitable if your project requires efficient cutting, consistent thickness, or if you’re looking for a more cost-effective option.