Plexiglass
Plexiglass, also known as acrylic, is a lightweight, crystal-clear alternative to traditional glass. It offers excellent optical clarity, is weather resistant, and is easier to handle than glass, making it a popular choice for both indoor and outdoor applications.
Acrylic is commonly used for storm windows, picture frame glazing, display cases, protective barriers, signage, cabinet doors, shelving, and craft or DIY projects. It is available in a variety of thicknesses and can be cut to custom sizes.
While acrylic is more impact resistant than standard glass, it is also more susceptible to scratching and is not recommended for applications where extreme impact resistance is required.
We can cut plexiglass to your required dimensions and can also provide a variety of thicknesses to suit your project.
Lexan
Lexan is a brand of polycarbonate sheet that is exceptionally strong and virtually unbreakable under normal use. It offers up to 250 times the impact resistance of standard glass, making it the ideal choice for applications where durability and safety are priorities.
Polycarbonate is commonly used for machine guards, safety shields, greenhouse panels, protective glazing, recreational vehicle windows, and other high-impact applications. It is lighter than glass and can be cut and fabricated to suit many different projects.
Compared to acrylic (plexiglass), Lexan is much more impact resistant but is generally more prone to surface scratching unless a hard-coated product is used.
We can cut Lexan to your specifications in a variety of thicknesses. If you’re unsure whether acrylic or polycarbonate is the best choice for your project, our team will be happy to help you choose the right material.
Plexiglass vs. Lexan
| Trade Names | Acrylic, PMMA | Polycarbonate |
| Brand Names | Crylux, Hesalite, Plexiglas, Acrylite, Lucite, and Perspex | Lexan, Makrolon |
| Material | Poly(methyl methacrylate); synthetic polymer derived from methyl methacrylate. It is a transparent thermoplastic, used as an engineering plastic | Polycarbonate resin thermoplastic; a solid substance that can deform in extreme heat (typically 147 degrees Celsius, or 297 degrees Fahrenheit) |
| Production | PMMA resin is melted down, but the process can vary. Either poured between two glass plates and then cooled, extruded through a mold to form sheets | The polycarbonate resin starts as small pellets; melted and cooled in flat molds |
| Impact Resistance | 17 times stronger than glass in impact resistance | 250 times stronger than glass in impact resistance; bends before breaking |
| Cutting | Can be cut using conventional cutting equipment; prone to chipping | Can be cut using conventional cutting equipment, slightly harder to cut through and will offer some initial resistance |
| Drilling | Prone to cracking if not drilled carefully and with the right bits, especially at the edges | Won’t crack when drilling |
| Bending | Requires heat before being bent; will soften gradually as the temperature is increased above 210°F (99°C). At temperatures from 340°F to 380°F (171°C to 193°C), it becomes soft and pliable and can be formed into almost any shape | Hot bending of Lexan polycarbonate can be done in several ways; however, cold bending of polycarbonate is much easier and is the more commonly chosen option |
| Chemical Resistances | Resistant to most chemicals, including many acids and bases unless they’re heavily concentrated. Can withstand detergents, oils, and fats. Do not use alcohol or ammonia to clean | Resistant to many bases and acids at non-concentrated levels. Good resistance to oils, greases, and fats. Resistant to ethanol, isopropanol, and other forms of alcohol |
| Temperature Resistances | Softening point at around 210F or higher. Reaches its melting point when temperatures reach or exceed 320F. | Slightly more temperature-resistant. Reaches its softening point above 300F. Reaches its melting point as temperatures exceed 400F. |
| UV Resistances | Very strong resilience to UV rays | Doesn’t stand up to UV rays as well; can yellow slightly after being exposed for a long period of time. |
| Clarity | Best; Glass-like | Good; prone to scratching |
Cutting and Drilling
Plexiglass
3mm or less (straight cuts): Scoring knife/plexiglass cutter
3mm or greater (straight cuts): Table saw or circular saw with fine-tooth carbide-tipped blade
Curved cuts: Jigsaw with fine-tooth blade
Choosing Blades
Table Saw / Circular Saw
Carbide-tipped, Fine-tooth Blade
60-80 teeth
Jigsaw
Fine-tooth, Bi-metal or Carbide Blade
20-30 teeth per inch (TPI)
Band Saw
Carbide-tipped, Fine-tooth Blade
6-12 teeth per inch (TPI)
Cutting
- Use clamps to secure the sheet and reduce vibration.
- Leave the protective film on during cutting.
- Use a slow, steady feed rate to avoid melting.
- Don’t rush, as overheating can melt the plastic.
- Don’t use a blade with too few teeth because it will chip.
Drilling
- Use a variable-speed drill capable of operating at low speed (500-1000 RPM).
- Use a plastic drill bit or a standard twist bit with the tip blunted. (Optional: Step drill bit for cleaner holes.)
- Use backing support (scrap wood underneath).
- Start with a pilot hole and use light pressure to avoid cracking.
- Don’t drill too close to the edge (stay at least twice the sheet thickness from the edge).
- Apply painter’s or masking tape over the drilling spot to reduce chipping and cracking.
- Don’t use metal bits at high speed as it can cause cracking or melting.
Fastening (Screws & Bolts)
- Drill oversized holes to allow for thermal expansion (about 1–2 mm larger than the screw).
- Use rubber washers or grommets to cushion the sheet.
- Use plastic screws or stainless steel fasteners for outdoor use.
- Don’t overtighten fasteners as it can crack Plexiglass.
- Don’t use self-tapping screws directly into the sheet without pre-drilling.
Bending
- Use a strip heater or heat gun for bending, along with a form or mold.
- Heat slowly and evenly along the bend line.
- Use a jig or form to hold the shape until cool.
- Don’t overheat as it causes bubbles or scorching.
- Don’t bend Plexiglass when cold as it is likely to crack.
Lexan
2mm or less: Utility knife
3mm or greater (straight cuts): Table saw or circular saw with carbide-tipped general-purpose blade
Curved cuts: Jigsaw or bandsaw
Choosing Blades
Table Saw / Circular Saw
Carbide-tipped, General Purpose Blade
40-60 teeth
Jigsaw
Fine-tooth, Bi-metal or High-carbon Steel Blade
18-24 teeth per inch (TPI)
Band Saw
Carbide-tipped, General Purpose Blade
10-14 teeth per inch (TPI)
Cutting
- Use clamps to secure the sheet and reduce vibration.
- Leave the protective film on during cutting.
- Use a slow, steady feed rate to avoid melting.
- Don’t rush! Overheating can melt the plastic.
Drilling
- Use a variable-speed drill capable of operating at low speed (500-1000 RPM).
- Use a plastic drill bit or a standard twist bit with the tip blunted. (Optional: Step drill bit for cleaner holes.)
- Use backing support (scrap wood underneath).
- Start with a pilot hole and use light pressure for clean, accurate holes.
- Don’t drill too close to the edge (stay at least twice the sheet thickness from the edge).
- Apply painter’s or masking tape over the drilling spot to reduce surface damage.
- Avoid using metal bits at excessively high speeds to prevent melting.
Fastening (Screws & Bolts)
- Drill oversized holes to allow for thermal expansion (about 1-2 mm larger than the screw).
- Use rubber washers or grommets to cushion the sheet.
- Use plastic screws or stainless steel fasteners for outdoor use.
- Don’t use self-tapping screws directly into the sheet without pre-drilling.
- Avoid overtightening, as it can stress the material, even though Lexan is much more impact-resistant than Plexiglass.
Bending
- Use a strip heater or heat gun for sharp bends, or cold-bend within the manufacturer’s recommended minimum bend radius.
- Heat slowly and evenly when using heat.
- Use a jig or form to hold the shape until cool.
- Don’t overheat as it can cause bubbling, warping, or discoloration.
- Unlike Plexiglass, Lexan can often be cold-bent without cracking, provided the bend radius is not too tight.