Introduction to Acrylic CNC Machining
Acrylic (PMMA) is a premier material for applications demanding exceptional optical clarity, light transmission, and aesthetic appeal. Valued for its glass-like transparency at a fraction of the weight, along with its superb machinability, it is the ideal choice for prototypes, light guides, displays, and countless consumer-facing products. At Clarwe, we leverage our specialized expertise and vast manufacturing network to machine both cast and extruded acrylic into precise, high-quality parts, all backed by our rigorous in-house quality assurance.
Key Advantages of Acrylic:
Acrylic vs. Other Transparent Materials
While materials like polycarbonate, glass, and ABS offer their own benefits, acrylic is the superior choice for applications where flawless optics, surface finish, and cost-effectiveness are critical. Compared to polycarbonate, acrylic offers better scratch resistance and optical clarity. Unlike glass, it is far lighter and much easier to machine into complex shapes. And versus standard plastics, it provides a premium, crystal-clear appearance.
| Material | Optical Clarity | Impact Strength | Machinability | Cost | Best For |
|---|---|---|---|---|---|
| Acrylic (PMMA) | Excellent | Good | Excellent | $$ | Displays, lenses, signs, aesthetic prototypes |
| Polycarbonate | Good | Very High | Good | $$$ | Bullet-proof glass, safety shields, high-impact parts |
| Glass | Excellent | Low (Brittle) | Difficult | $$ | Windows, lenses (where machining not required) |
| ABS | Opaque | High | Excellent | $ | Enclosures, functional prototypes, non-transparent parts |
Acrylic Types and Selection Guide: Cast vs. Extruded PMMA
Choosing between cast and extruded acrylic is the most critical decision for your project, directly impacting the final part's clarity, precision, and performance. At Clarwe, we machine both types to perfection, leveraging our network of specialized partners and in-house QA to ensure your material choice delivers exactly what your design requires.
Cast vs. Extruded Acrylic: A Detailed Comparison
Cast Acrylic
The premium choice for precision. Its higher molecular weight and slower curing process result in superior optical clarity, excellent chemical resistance, and better tolerance control during machining, making it ideal for lenses, signs, and high-end displays.
Extruded Acrylic
The cost-effective solution for volume. The continuous extrusion process creates a material that is more flexible and easier to thermoform. It is perfectly suited for less critical applications like display fixtures, light covers, and simple prototypes where ultimate optical perfection is not the primary goal.
Technical Specifications: Cast vs. Extruded Acrylic
| Property | Cast Acrylic | Extruded Acrylic | Ideal For |
|---|---|---|---|
| Molecular Weight | Higher | Lower | Cast: Precision machining, intricate details |
| Tolerance Control | Excellent (±0.005") | Good (±0.010") | Cast: Tight-tolerance parts |
| Optical Clarity | Superior (92% light transmission) | Very Good (90% light transmission) | Cast: Lenses, optical components |
| Machinability | Excellent (less prone to chipping) | Good (can chip more easily) | Cast: Complex geometries |
| Cost | Higher | Lower | Extruded: Cost-sensitive projects |
| Best Applications | Optical lenses, precision parts, engraved signs | Display fixtures, simple prototypes, basic enclosures | Based on requirement |
How to Choose the Right Acrylic for Your Project
Your choice ultimately depends on the application's demands. Need flawless optics and tight tolerances for a critical component? Cast acrylic is the only choice. Producing a large run of simple, cost-effective light diffusers? Extruded acrylic will perform perfectly while keeping your budget on track.
Unsure which material is the perfect fit? Our engineers provide expert guidance during our complimentary Design for Manufacturability (DFM) review, recommending the optimal acrylic type to balance performance, aesthetics, and cost for your specific part.
CNC Machining Capabilities for Acrylic
At Clarwe, we specialize in transforming pristine acrylic sheets and blocks into crystal-clear, precision components. Our comprehensive manufacturing network and in-house expertise allow us to select the optimal process—from CNC machining to injection molding—for your specific application, ensuring flawless optics, tight tolerances, and superior surface finishes every time.
CNC Milling Services
Our CNC milling is perfect for creating complex shapes, intricate cut-outs, and precise features in acrylic. Using specialized tooling and carefully calibrated parameters, we achieve optically clear edges and minimize stress cracking, making it ideal for lenses, light guides, and display components.
- ⇒ 3, 4 & 5-Axis Machining: Create complex 3D contours, undercuts, and deep cavities with exceptional accuracy.
- ⇒ High-RPM Spindles: Achieve superior surface finishes and prevent material melting with speeds up to 24,000 RPM.
- ⇒ Specialized Acrylic Tooling: Single-flute and O-flute end mills designed for clean, chip-free cuts in acrylic.
- ⇒ Micro-Machining: Precision features and engraving down to 0.5mm with extreme detail.
CNC Turning Services
For round acrylic parts like knobs, lenses, and cylindrical light pipes, our CNC turning services deliver excellent concentricity and smooth finishes. We expertly manage cutting feeds and speeds to achieve brilliant clarity on curved surfaces.
- ⇒ Precision Lathes: Create round parts and diameters with tight tolerances and excellent surface quality.
- ⇒ Live Tooling: Mill and drill features during the turning operation for complex parts in a single setup.
- ⇒ Surface Finishing: Achieve optical-quality finishes on curved surfaces directly from the machine.
CNC EDM Services
For the most demanding acrylic components requiring extreme precision and no tooling pressure, our Electrical Discharge Machining (EDM) services deliver unmatched results. This process is ideal for creating intricate features without the risk of cracking or stressing the material.
- ⇒ Wire EDM: Precision cutting of intricate profiles and sharp internal corners with tolerances to ±0.002mm.
- ⇒ Sinker EDM: Create complex 3D cavities, textures, and micro-features in acrylic blocks.
Injection Molding Services
For high-volume production of acrylic parts, our injection molding capabilities deliver exceptional consistency and cost-effectiveness. We produce parts with brilliant clarity and complex features at scale.
- ⇒ Optical-Grade Molds: Precision machined molds that produce parts with minimal visible gate marks.
- ⇒ PMMA Granulate: High-quality acrylic feedstock for superior clarity and mechanical properties.
- ⇒ Clean Room Production: Ensures dust-free environments for optically critical components.
Urethane Casting Services
For medium-volume requirements or when testing designs before hard tooling, urethane casting produces high-quality acrylic-like parts with quick turnaround times.
- ⇒ Silicon Molds: Create functional prototypes and small batches with properties similar to acrylic.
- ⇒ Clear Resins: Achieve transparency levels approaching manufactured acrylic parts.
- ⇒ Rapid Iteration: Perfect for design validation and market testing before production.
Technical Specifications at a Glance
| Process | Tolerance Capability | Standard Lead Time | Max Part Size | Best For |
|---|---|---|---|---|
| CNC Milling | ±0.05mm | 2-4 days | 1500x800x500mm | Prototypes, complex parts, displays |
| CNC Turning | ±0.075mm | 3-5 days | Ø300mm x 500mm | Round parts, knobs, cylindrical components |
| CNC EDM | ±0.002mm | 5-7 days | 400x300x200mm | Intricate details, stress-free cutting |
| Injection Molding | ±0.05mm | 4-6 weeks | 500g shot size | High-volume production, complex shapes |
| Urethane Casting | ±0.1mm | 5-10 days | 1000x1000x500mm | Medium batches, prototypes, bridge production |
Whether you need precision machining, high-volume molding, or prototype casting, our team has the expertise and equipment to manufacture your acrylic parts to the highest optical standards. We combine advanced technology with material expertise to deliver crystal-clear results for your most demanding applications.
See Our Full CNC Capabilities | Request a Free Consultation | Explore Available Acrylic Types
Surface Finishing Options for Acrylic Parts
Elevate your machined acrylic components with our comprehensive suite of surface finishing services. From achieving optical clarity to adding decorative or functional textures, we provide the perfect finish to enhance both the appearance and performance of your clear parts, all backed by our rigorous in-house quality inspection.
Polishing & Smoothing Services
Achieve brilliant, crystal-clear edges and surfaces that maximize light transmission and create a premium aesthetic:
• Flame Polishing: Creates a perfectly smooth, optical-quality finish on edges through controlled heating.
• Diamond Polishing: Mechanical polishing for superior clarity and a glass-like finish on flat surfaces.
• Vapor Polishing: Chemical process that eliminates microscopic surface imperfections for ultimate clarity.
• Buffing & Lapping: Mechanical methods to achieve specific surface finishes and reduce visible machining lines.
Coating & Hardening Options
Protect your acrylic parts from scratches, UV damage, and environmental factors while maintaining optical properties:
• Anti-Scratch Coating: Applied protective layer that significantly increases surface durability and wear resistance.
• UV-Resistant Coating: Protects against yellowing and degradation from prolonged sunlight exposure.
• Anti-Reflective (AR) Coating: Reduces surface reflections for applications requiring maximum light transmission.
• Conductive Coating: Adds EMI/RFI shielding properties while maintaining transparency.
Texturing & Decorative Finishes
Add visual interest, diffuse light, or create unique tactile surfaces for your acrylic components:
• Laser Etching: Precise, permanent marking for logos, serial numbers, or decorative patterns.
• Frosting & Satin Finishes: Creates a uniform matte appearance that softly diffuses light.
• Patterned Textures: Apply custom textures for improved grip or specific visual effects.
• Sandblasting: Produces a consistent, non-glare surface that hides fingerprints and scratches.
Specialty & Custom Finishes
Unique finishing solutions for specific applications and aesthetic requirements:
• Tinting & Dyeing: Add consistent, vibrant color throughout the material while maintaining transparency.
• Metallization: Apply thin metallic coatings for mirrors or reflective surfaces.
• Printing & Graphics: Direct printing for custom designs, indicators, or branding.
• Edge Lighting Preparation: Specialized finishing for applications using LED edge lighting effects.
Acrylic Surface Finishing Comparison
| Finish Type | Clarity | Durability | Light Transmission | Best Applications |
|---|---|---|---|---|
| Flame Polishing | Optical | Good | 92%+ | Display edges, lenses, light guides |
| Vapor Polishing | Optical | Excellent | 92%+ | Medical devices, optical components |
| Anti-Scratch Coating | Clear | Excellent | 90-92% | Touch screens, protective covers |
| Anti-Reflective Coating | Enhanced | Good | 99%+ | Lenses, display windows, optics |
| Frosted Finish | Diffused | Good | 70-80% | Light diffusers, decorative panels |
Whether you need optical clarity for lenses, durability for touch surfaces, or decorative effects for displays, our finishing experts will recommend the optimal solution for your acrylic components. Every finish is applied with strict quality control to ensure consistent results that meet your exact specifications.
Acrylic CNC Machining Applications by Industry
From prototype to production, acrylic's exceptional clarity and versatility make it the material of choice for innovations across diverse sectors. At Clarwe, we've partnered with designers and engineers to create precision acrylic components that meet the unique demands of these industries, backed by our rigorous quality assurance and extensive manufacturing network.
Medical & Healthcare
Where clarity and cleanliness are critical, our machined acrylic components meet stringent medical standards for devices that save lives and improve patient outcomes.
• Medical device windows and inspection ports
• Surgical instrument handles and clear housings
• Laboratory equipment and sample containers
• Diagnostic device components and light guides
• Pharmaceutical display stands and packaging
Optics & Lighting
Harnessing acrylic's brilliant light transmission properties, we create components that manipulate and enhance light with precision and beauty.
• Light pipes and guides for LED applications
• Optical lenses and light diffusers
• Reflectors and light directing components
• Signage and channel letters for illumination
• Museum and gallery lighting components
Retail & Display
Create captivating visual experiences with crystal-clear acrylic components that showcase products while withstanding the demands of high-traffic environments.
• Product display stands and risers
• Retail signage and point-of-purchase displays
• Exhibition stands and trade show components
• Protective barriers and sneeze guards
• Menu boards and pricing displays
Automotive & Transportation
From concept vehicles to production models, acrylic components provide durability and optical excellence for both interior and exterior applications.
• Interior light guides and instrument clusters
• Concept vehicle prototypes and show car components
• Lighting covers and lens applications
• Display screens and protective covers
• Custom automotive badges and emblems
Electronics & Technology
As devices demand both functionality and aesthetics, our precision acrylic components provide the perfect blend of optical performance and durable protection.
• Electronic device housings and enclosures
• Touch screen interfaces and protective overlays
• LED lighting components and diffusers
• Control panel windows and indicator lenses
• Virtual reality and augmented reality components
Consumer Products & Specialty Applications
From everyday items to specialty equipment, acrylic's versatility enables innovative products that combine form and function.
• Award and recognition products
• Architectural models and prototypes
• Artistic installations and sculptures
• Marine instrumentation and boat components
• Protective equipment visors and shields
Industry Applications at a Glance
| Industry | Acrylic Types | Key Requirements | Typical Components |
|---|---|---|---|
| Medical | Cast Acrylic | Optical clarity, chemical resistance | Device windows, inspection ports |
| Optics & Lighting | Optical Grade Cast | Light transmission, precision | Light guides, lenses, diffusers |
| Retail & Display | Extruded, Cast | Durability, aesthetic appeal | Display stands, signage, barriers |
| Automotive | Impact-Modified | UV resistance, durability | Light covers, instrument clusters |
| Electronics | Cast, Anti-Static | Clarity, protective qualities | Enclosures, touch screen overlays |
No matter your industry or application, our engineering team understands the unique material requirements and performance needs of your sector. We deliver acrylic components that not only meet specifications but exceed expectations for optical performance, aesthetic quality, and durability.
Quality Assurance and Certifications for Optical Components
At Clarwe, optical perfection isn't just a goal—it's our standard. Our comprehensive quality management system ensures every acrylic component meets the highest standards of clarity, precision, and performance. From prototype to production, we deliver consistently brilliant results you can trust for even the most demanding optical applications.
| Certifications & Compliance |
We maintain rigorous certifications that demonstrate our commitment to excellence across all industries: ISO 9001:2015 Certified: Quality management system certification ISO 13485:2016 Certified: Medical device quality management USP Class VI Compliance: Material safety certification for medical applications ISO 10993 Biocompatibility: Medical device material safety standards RoHS & REACH Compliance: Environmental and material safety standards |
| Quality Control Processes |
Our multi-stage inspection process ensures every optical component meets your exact specifications: First Article Inspection (FAIR): Comprehensive initial part validation including optical properties In-Process Inspection: Real-time quality checks during machining and finishing Final Optical Inspection: Complete verification of clarity, surface quality, and dimensions Light Transmission Testing: Quantitative measurement of optical properties Documentation Package: Complete quality records with every order |
| Advanced Inspection Equipment |
We invest in specialized metrology equipment to verify optical perfection: Non-Contact CMM: ±0.005mm accuracy without surface marking Optical Comparators: 2D profile measurement with 20x magnification Surface Roughness Testers: Quantitative surface finish validation Light Transmission Meters: Precise measurement of clarity and haze Digital Microscopes: 200x magnification for surface quality inspection |
| Quality Documentation |
We provide comprehensive documentation with every order: • Certificate of Conformity: Material and specification compliance • First Article Inspection Reports: Detailed initial part validation • Material Certifications: Optical grade verification and traceability • Inspection Reports: Complete dimensional and optical validation data • Surface Quality Reports: Quantitative finish measurements |
| Industry-Specific Compliance |
Our quality systems meet the strict requirements of regulated industries: • Medical: ISO 13485, USP Class VI, biocompatibility documentation • Optical: Light transmission certification, haze measurement reports • Consumer Electronics: Cosmetic inspection standards, AQL sampling • Automotive: PPAP documentation, environmental resistance testing • Aerospace: Dimensional validation, material certification |
Optical Quality Capabilities Overview
| Inspection Method | Accuracy Capability | Best For | Industry Applications |
|---|---|---|---|
| Non-Contact CMM | ±0.005mm | Complex 3D geometries without surface damage | Medical, aerospace optics |
| Light Transmission Testing | ±0.1% | Optical clarity and haze measurement | Lighting, display components |
| Surface Roughness | ±0.001μm | Surface finish validation | Optical lenses, light guides |
| Visual Inspection | N/A | Cosmetic defects, inclusions, clarity | Consumer products, displays |
| Coordinate Measurement | ±0.002mm | Dimensional accuracy verification | Precision optical components |
From raw material selection to final optical inspection, our quality assurance team ensures every acrylic component meets your exact requirements. We don't just measure dimensions—we validate optical perfection through comprehensive testing that gives you complete confidence in every transparent component we deliver.
Get a Project Review | Contact Our Engineering Team | Request a Callback
Design Guidelines for Acrylic CNC Machining
Designing acrylic parts requires special consideration for its unique properties—exceptional clarity but also brittleness. Follow these expert guidelines to ensure your designs maximize optical quality while maintaining structural integrity. Our engineering team provides free Design for Manufacturability (DFM) analysis to help optimize your acrylic parts before production.
Key Design Considerations
- Wall Thickness: Maintain minimum 1.5mm wall thickness for structural stability
- Internal Corners: Use generous radii (minimum 0.5mm) to prevent stress cracking
- Hole Depth: Limit through holes to 3x diameter, blind holes to 2x diameter
- Edge Quality: Design for machined edges to be hidden or polished in final assembly
- Text Engraving: Minimum 1mm character height with bold, sans-serif fonts for readability
- Tolerances: Specify critical dimensions only (±0.1mm standard, ±0.05mm achievable)
Standard Machining Tolerances
- Standard Machining: ±0.1mm (±0.004")
- Precision Machining: ±0.05mm (±0.002")
- High-Precision: ±0.025mm (±0.001") with specialized processes
- Surface Finish: Standard Ra 1.6μm, optical polishing Ra 0.2μm achievable
Recommended Design Parameters for Acrylic
| Feature Type | Recommended Value | Minimum Value | Design Tip |
|---|---|---|---|
| Wall Thickness | 3.0mm | 1.5mm | Use ribs or gussets for structural support on larger parts |
| Internal Corner Radius | 1.0mm | 0.5mm | Larger radii prevent stress concentration and cracking |
| Hole Diameter | Standard drill sizes | 1.0mm | Depth ≤ 3x diameter to prevent tool deflection |
| Threading | Avoid in thin walls | M3 minimum | Use heat-set inserts instead of direct threading |
| Text Engraving | 2mm character height | 1.0mm | Use bold fonts and increase width-to-height ratio |
| Minimum Feature Size | 2.0mm | 1.0mm | Consider material brittleness for thin features |
Design for Manufacturing Tips
• Avoid Sharp Corners: Use radii everywhere possible to prevent stress points
• Consider Material Type: Design thicker walls for extruded acrylic than cast
• Minimize Deep Pockets: Reduce depth-to-width ratio to prevent tool chatter
• Design for Polishing: Specify which edges require optical finishing
• Avoid Thin Extensions: Design robust features that won't vibrate during machining
• Account for Expansion: Leave clearance for thermal expansion in fitted parts
• Specify Critical Surfaces: Identify which faces must remain scratch-free
Cost-Saving Design Strategies
• Simplify Geometry: Avoid complex 3D contours when possible
• Standardize Features: Use standard hole sizes and avoid custom radii
• Design for Single Setup: Minimize part reorientation during machining
• Group Similar Finishes: Specify polished areas strategically
• Avoid Small Features: Eliminate tiny holes and delicate protrusions
• Use Stock Sizes: Design parts to fit standard acrylic sheet dimensions
• Minimize Secondary Operations: Design parts that require minimal hand finishing
Design for Assembly Considerations
• Clearance Fits: Allow 0.2mm clearance for press fits to prevent cracking
• Fastener Selection: Use washers and avoid overtightening
• Thermal Expansion: Account for different expansion rates with other materials
• Stress Distribution: Design mounting points to distribute load evenly
• Protection Features: Include protective films or covers in critical areas
Even if your design doesn't follow all these guidelines, our engineers can help optimize it for manufacturing. Upload your CAD files for a free DFM analysis and online quote to see how we can transform your acrylic designs into crystal-clear reality with precision and efficiency.
Why Choose Clarwe for Acrylic CNC Machining?
When optical clarity and precision matter, designers and engineers trust Clarwe for their critical acrylic components. We combine specialized material expertise with rigorous quality control to deliver crystal-clear results that automated platforms simply can't match. Here's what sets us apart:
Unmatched Acrylic Expertise
➤ Cast & Extruded Specialists: Expert guidance on material selection for your specific application
➤ Optical-Grade Machining: Dedicated processes for achieving superior clarity and surface finish
➤ Same-Day Quoting: Real engineers review your files and provide quotes within hours, not days
➤ Free DFM Analysis: Detailed design feedback to optimize your part for optical performance
Precision You Can See
➤ Tight Tolerances to ±0.05mm: Achievable with our non-contact CMM inspection
➤ First-Time Quality: 99.3% on-time delivery with 100% quality inspection
➤ ISO 13485 & ISO 9001 Certified: Meeting medical and industrial quality standards
➤ In-House Optical Lab: Light transmission testing and surface quality verification
The Clarwe Advantage: Engineer-Led Manufacturing
➤ Unlike automated platforms, every Clarwe project receives personal engineering oversight from quote to delivery
➤ Our dedicated engineers become an extension of your team, providing proactive solutions and expert guidance throughout your project
Clarwe vs The Competition
| Capability | Clarwe | Typical Machine Shops | Online Platforms |
|---|---|---|---|
| Engineering Support | Dedicated Engineer | Limited or Extra Cost | Automated Only |
| Quality Control | In-House Optical Inspection | Variable | Partner-Dependent |
| Material Options | Cast & Extruded Expertise | Limited Selection | Basic Options |
| Design Feedback | Free DFM Analysis | Often Additional Cost | Generic Suggestions |
| Optical Testing | Light Transmission Verification | Rarely Available | Not Offered |
| Lead Time | 2-4 Day Prototyping | 1-2 Weeks | 3-5 Days |
Seamless Process, Perfect Results
➤ Online Quoting: Upload your CAD file for immediate pricing➤ Real-Time Project Tracking: Monitor your order with photo updates at every stage
➤ Comprehensive Documentation: Receive full inspection reports and material certs
➤ Dedicated Support: Single point of contact throughout your project
Global Capacity, Local Attention
➤ 520+ Manufacturing Partners: Global network with specialized acrylic expertise➤ Risk-Free Sourcing: We manage quality across our entire partner network
➤ Scalable Production: From 1 prototype to 50,000+ production parts
➤ No Tooling Fees: Competitive pricing with no hidden costs
Join thousands of designers and engineers who have made Clarwe their trusted manufacturing partner for acrylic components. Experience the difference that engineer-led manufacturing makes—upload your CAD files today for a free, no-obligation quote and detailed DFM analysis.