ACRYLITE® LED sign grade (Resist SG)
Fabrication Manual
Introduction
the sheet to the cutting surface (when operating a
ACRYLITE® LED sign grade is an impact modified
vertical saw or panel saw) or providing the proper
acrylic specifically developed to meet the unique
pressure on a table saw.
needs of the sign industry. It is ten times stronger
than standard acrylic so it will resist breakage
Moderate feed rates, in the 15-25 ft/min range,
during storage, fabrication, shipping and
will ensure a proper cut. A chipped edge indicates
installation. Ideal for any sign application,
that the feed rate is too fast or that the material is
ACRYLITE® LED sign grade offers:
vibrating too much, while a melted edge indicates
that the feed rate is too slow. It is recommended
• superior light transmission
that the feed rate be decreased at the end of the
• excellent light diffusion with LED light sources
saw cut, especially on thinner sheets. This will
• outstanding weatherability
prevent chipping and blowout of the exit edge.
• easy fabrication
Cutting Operations
Cutting With Table and Panel Saws
Generally, straight cuts are made using a
conventional table or panel saw. A saw blade
specifically designed for acrylic, such as a triplechip grind, carbide toothed saw blade works best.
For a 10 inch saw blade, 80 teeth are
recommended. For larger blades, equivalent tooth
spacing can be utilized with good results. On a
triple-chip grind saw blade, every other tooth has
a beveled cutting edge which aids in chip removal
Panel saw cutting
and reduces heat buildup.
Jigsaw Cutting
When cutting ACRYLITE® LED sign grade, the
blade should protrude 1/2” to 1” above the
surface of the sheet, with optimum results usually
obtained using a 3/4” blade height. Vibration
should be kept to a minimum, either by clamping
Hand held jigsaws work well with ACRYLITE® LED
sign grade when cutting intricate shapes and
letters. Results comparable to those achieved with
cell cast acrylic sheet are possible. For best
results, use a wavy-set type blade with 8-13
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teeth/inch (tpi). This blade configuration will
Scribing and Breaking
typically chip cell cast acrylic, but will work very
ACRYLITE® LED sign grade sheet can be scribed
well with ACRYLITE® LED sign grade due to the
and broken similarly to ACRYLITE® cast and
sheet’s inherent toughness. Using a blade with a
extruded acrylic sheet. Scribing should only be
higher number of teeth per inch, 18-24 tpi, may
done on the 0.118” (3 mm) thickness. With the
result in melting along the cut edge. It is also
aid of a straight edge to guide the scribing tool,
important to ensure the blade is sharp – do not
pull the scribing tool across one side of the sheet
use a blade that has already been used for cutting
surface several times until the tool has penetrated
metal or other materials.
approximately 1/16” through the material. Next,
position the sheet so that the scribed line is just
When jigsaw cutting, it is important to minimize
beyond the edge of the working surface. While
vibration by clamping the material to a firm
holding the sheet firmly in place on the surface
surface. Feed rates in the 8-12 ft/min range will
near the scribed line, apply a quick, downward
yield the best results.
pressure to the end of the sheet overhanging the
working surface.
Bandsaw Cutting
Bandsaws are typically used for quick, rough cuts,
Routing Operations
as well as intricate shapes and letters. As with
Hand Held and Table Routers
jigsaw cutting, the quality of the edge is
ACRYLITE® LED sign grade can be routed with the
dependent on the type of blade used. Generally,
same equipment used for routing standard acrylic
blades in the raker style with teeth in the 8-13 tpi
sheet. Because ACRYLITE® LED sign grade sheet is
range will produce the best results. Blades with
not as stiff as conventional acrylic, particular care
fewer teeth per inch will leave a jagged, rough
must be taken to eliminate the vibration of the
edge while blades with a higher number of teeth
work piece during the routing operation. If
per inch will yield a smoother edge. If blades with
vibration is present, it can result in a chipped
more teeth per inch are used, it is recommended
edge. To support thin material, 0.060 and 0.080
to utilize a coolant such as water, compressed air,
(1.5 mm and 2.0 mm) thick, during routing,
or a combination of both to reduce melting along
sandwich the material between stiffer plastic
the cut edge. Feed rates in the 10 to 15 ft/min
sheets.
range will yield the best edge.
When compared to feed rates for routing
standard acrylic sheet, ACRYLITE® LED sign grade
sheet’s feed rates are noticeably faster.
ACRYLITE® LED sign grade is less prone to
chipping than standard acrylic sheet, particularly
when entering and exiting a cut. Both materials
are notch sensitive. Any notches in an edge can
propagate into a crack under load conditions.
During plunge cutting, the cutter has a tendency
to grab as it penetrates through the sheet. Take
Bandsaw cutting is easily accomplished with ACRYLITE®
LED sign grade Sheet
special care to hold the sheet firmly. Exit the
material slowly to avoid chipping or cracking
during plunge routing. A safer option to plunge
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routing is to drill an adequately oversized hole
multiple passes should be made. Using coolant
and begin routing at this location.
and minimizing cut depth helps to reduce melting
caused by heat build-up and/or inadequate chip
Carbide tipped, 1/2 diameter, two-flute, straight
removal.
bits are recommended.
Two-flute, spiral-up and O-flute design bits
CNC Routing
made from solid carbide are recommended for
As with all routing, it is important to ensure that
most applications.
the material is firmly held and supported to
prevent vibration. This is even more critical with
Rotational speeds of 16,000 to 18,000 RPM’s and
CNC routing because tool speeds and feed rates
feed rates of 100 to 300 in/min will produce the
are usually much higher than with handheld or
best results with 3/8” and 1/2” diameter bits. For
hand-fed routers.
smaller bits rotational speeds of 18,000 to
20,000 RPM’s with feed rates of 100 to 200
In general, much higher feed rates are possible
in/min range will produce the best edge and tool
with ACRYLITE® LED sign grade sheets than with
life.
standard acrylic sheets. When using bits that are
1/4 in diameter or larger, rotational speeds of
It is important to note that dust/chip collection
18,000 RPM and feed rates of 200 in/min will
systems as well as coolants such as compressed
produce good results on most equipment. On
air, mist coolants and cold air/vortex tube
large, stable, well maintained machines with very
technology, will greatly reduce the heat build up
solid fixturing, feed rates of up to 600 in/min are
and improve the quality of the edge and life of
possible.
the tool.
Laser Cutting and Engraving
ACRYLITE® LED sign grade can be successfully
laser cut and laser engraved. Typically CO2 lasers
are employed in sizes ranging from 25 watts to
400 watts per laser head. The primary benefit of
using a higher powered laser is to increase
cutting speed. Additionally, larger lasers often
come equipped with an air or gas assist and a
vacuum table. Both of these options help to
remove vapors generated during the cutting
Routing
For smaller diameter bits (1/8 and 1/16),
rotational speeds of 20,000 RPM coupled with
feed rates in the 150 – 200 in/min range are
recommended provided that the router bits are
cooled. Coolants such as compressed air or mist
cooling systems can be used. In addition,
consideration must be given to the depth of cut.
operation leading to improved results.
When laser engraving ACRYLITE® LED sign grade,
start with the same operating parameters as used
with continuously manufactured or extruded
acrylics. The resulting engraved designs will have
a relatively clear appearance (the same as with
continuously manufactured and extruded acrylic
sheet). The engraved images will not be as white
For best results the cut depth should be no more
than 1.5 x the bit diameter. For deeper cuts,
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as those achieved when engraving cell cast acrylic
sheet.
When laser cutting ACRYLITE® LED sign grade it is
especially advantageous to have a vacuum table
and gas assist option. The gases generated
during the laser cutting operation can deposit on
the edges of ACRYLITE® LED sign grade and form
a tacky film. Efficient removal of vapors
minimizes this problem. The tacky deposits can
Modification of metal working drill bits for plastic.
be removed by wiping the laser cut edges
Twist Drills
afterwards with VM&P naptha, which can be
ACRYLITE® LED sign grade drills cleanly with
obtained at most hardware stores.
high-speed steel (modified for plastic) twist drills
(see illustrations on left and above). On large
Drilling Operations
diameter holes, it is recommended to pilot drill
Because ACRYLITE® LED sign grade is not as stiff
first before enlarging the hole to the final
as conventional acrylic sheet, it has a tendency to
dimension. Adjust speed and feed rates so that a
lift off the machining table when drill bits exit the
controlled chip is produced with no melting of the
hole. To compensate, clamping devices need to
plastic. Continuous chips are not readily
be placed as close as possible to the hole being
produced when drilling ACRYLITE® LED sign grade
drilled, carefully allowing for clearance of the
sheet, nor are they required for excellent drilled-
rotating spindle and cutter. Several hold-downs
hole finishes.
may be required to firmly hold thinner stock flat
to the machining table. Wherever possible,
Rotational speeds in the 500 -1000 rpm range,
ACRYLITE® LED sign grade should be drilled on
combined with feed rates in the 3-12 in/min
stationary equipment. Portable electric hand drills
range will usually give good results.
should only be used as a final option and for
small diameter holes only.
Standard twist drills can also produce satisfactory
holes in ACRYLITE® LED sign grade. To avoid
sheet notching, securely clamp the material to the
machine table and apply slow entry and exit
feeds.
Proper backing material such as plywood or
another piece of acrylic should be used when
drilling ACRYLITE® LED sign grade sheet. The
backing material will help prevent chipping of the
bottom surface. When drilling stacks of sheet, it
is a good idea to utilize a coolant such as water
or kerosene. This will minimize heat build up and
create holes with smooth walls.
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Spade Bits
the tool, results in a controlled cut with little
Spade bits with side spurs (i.e. IRWIN 2000
chatter and plenty of chip clearance. Pilot drilling
Speedbores) produce satisfactory holes in
is necessary when using the countersink design.
ACRYLITE® LED sign grade. The drilling is done in
The pilot hole should be oversized with reference
two steps with reduced machine speed for large
to the shank of the fastener
diameter bits. Step one: Drill one face of the sheet
to lightly score the perimeter of the hole. Step
Edge Finishing Operations
two: Flip the material and complete drilling from
The same edge finishing operations that work
the opposite face of the sheet.
well with standard acrylic sheet can be used to
obtain excellent edge finishes with ACRYLITE®
CAUTION: The original Speedbores, without side
LED sign grade. However, care must be taken in
spurs, are not recommended for drilling
certain edge finishing operations, such as flame
ACRYLITE® LED sign grade.
polishing, to ensure the best edge quality. This
section will cover proper techniques to ensure an
Circle Cutters
edge finish of the highest quality.
Circle cutters can be used for cutting large
diameter holes in ACRYLITE® LED sign grade.
Wet Sanding and Scraping
Sharp cutters along with multiple hold-down
Wet sanding will yield a smooth, matte-finish
devices are essential. A single clamping device is
edge and is suitable for use prior to flame
inadequate for circle cutters; should the cutter
polishing. Dry sanding is not recommended as it
grab, the sheet can pivot and dangerously kick-
will lead to a highly stressed and melted edge. To
out towards the operator. For thinner gauge
obtain the smoothest edge, start with a 240 grit
material (.098” or less), lightly score the
“wet and dry” sand paper and use plenty of water.
perimeter of the hole from one face, then flip the
The use of water will keep edge stresses to a
material to complete drilling from the opposite
minimum by acting as a coolant. Finer finishes
face of the sheet. This practice will eliminate
can be obtained by sanding with 240 grit, then
notching on the edges and grabs, to which
stepping up to 400, 600, and 800 grit, depending
thinner stock is prone.
on the desired finish.
Hole Saws
The use of belt sanders may result in melting and
Hole saws also produce acceptable holes in
high stress. If using a belt sander, it is important
ACRYLITE® LED sign grade. Although less smooth
to use light pressure when sanding. Excessive
than other hole cutting means, best results are
pressure will increase frictional heat buildup
achieved with sharp hole saws tipped with
causing the edge to melt and gum.
carbide. Because of the high friction produced by
these cutting tools, a coolant solution of
Hand scraping is an alternative to sanding for
detergent and water or kerosene will help to
preparing the edges of a sheet for polishing. The
minimize melting of the material.
sheet can be scraped with almost any type of
sharp, flat metal edged tool. Holding the scraper
Countersinking
vertically, at a 45° angle to the edge, scrape the
Countersinking in ACRYLITE® LED sign grade is
sharp edge of the sheet by drawing the tool
best done with a non-fluted (Weldon) countersink
across the edge with firm but steady pressure. A
design. The large land of this cutter combined
continuous strip should peel as the tool is drawn
with the oblique hole forming the cutting edge of
along the edge. There are tools available that will
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reduce the sharpness of both edges at the same
compound will provide a high luster edge in a
time. It is important to note that scraping will not
short time.
provide the smoothness of a sanded or polished
edge.
Removal of Whitening
Whitening within ACRYLITE® LED sign grade
Jointing
occurs under extreme impact or if the material's
Jointing of ACRYLITE® LED sign grade will produce
edge or face is mechanically stressed. This
a smooth, machined edge. Knives made from
whitening can be removed by heating both sides
high-speed steel or carbide will work well. Blade
of the affected area at approximately 185°F. Apply
height should be set to remove approximately
heat evenly and long enough for the full thickness
1/32” from the sheet. The most important aspect
of sheet to reach the desired temperature.
of jointing is controlling the feed rate. It is
Overheating will cause distortion. A heat gun or
important to use a steady, even feed rate while
an industrial oven can be used for eliminating
holding the sheet material firmly to the guide
whitening. Heating ACRYLITE® LED sign grade
fence. Excessive feed rates will result in a
with a torch is not recommended.
chipped, highly stressed edge.
Note: Hazing is noticeable during the heating
Edge Finishing Machines
cycle. When the sheet returns to room
Commercially available edge finishing machines
temperature, the hazing disappears.
offer a fast method of obtaining smooth edges
without sanding or scraping. Finishes will range
Flame Polishing
from smooth, matte-finish to almost polished
Highly polished edges can be obtained by flame
edges, depending on the design of the machine
polishing using the same techniques used with
and cutting tools used. Edge finishing machines
standard acrylic with slight modifications. When
are ideal for preparing sheet for subsequent edge
flame polishing ACRYLITE® LED sign grade, a
finishing steps, such as flame polishing and
cooler flame should be used than with standard
buffing, or fabrication steps such as cementing.
acrylics. This is best accomplished using MAPP
Care should be taken to adjust the feed rate to
gas.
eliminate chipping and melting of the material.
Fast feed rates will result in chipping while slow
Another option is to use a hydrogen/oxygen
feed rates will result in melting. In general, faster
welding torch. Make sure to reduce the oxygen
feed rates can be used for edge finishing
content to produce a flame that is bright
ACRYLITE® LED sign grade than for standard
orange/red in color, as opposed to the bluish,
acrylic sheet.
almost invisible flame typically used with
standard acrylics. ACRYLITE® LED sign grade has
Buffing
a tendency to turn a milky white color when
Buffing the edges of ACRYLITE® LED sign grade
overspray from the flame contacts the surface of
will produce a high luster finish. It is
the sheet. It is important to minimize this contact
recommended that the edge be scraped, then wet
by using a quicker feed rate than would normally
sanded prior to buffing. A stationary buffing
be used for standard acrylics. Hold the torch at an
wheel or portable polishing head can be used.
angle and draw the flame along the edge of the
Loose stitched, bleached muslin wheels, used in
sheet. Practice will help you to estimate the speed
combination with a medium to fine buffing
and distance. If the first pass does not produce a
completely polished edge, allow the piece to cool,
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and then try a second pass. For optimum edge
inconsistent surface contact and air bubbles in
finish, wet sand the edge or pass the sheet
the joint.
through an edge finishing machine or jointer to
remove any tooling marks from previous
Note:
Note: Never cement flame polished edges. This
operations prior to flame polishing.
operation creates high levels of internal stress in
the material and could lead to crazing.
Cementing Operations
ACRYLITE® LED sign grade can be easily and
quickly cemented to itself, other acrylic materials,
as well as to trim cap, creating strong bonds in
applications such as channel letters. ACRYLITE®
LED sign grade offers faster setup times than cell
cast acrylic sheet products. Acrylic cements such
as ACRIFIX® solvent cements work well on
ACRYLITE® LED sign grade. Generally, techniques
used to cement standard acrylics can be used
with success on ACRYLITE® LED sign grade.
Trim Cap
When making channel letters, make sure all areas
are in contact with the trim-cap, and apply a
generous amount of cement around the perimeter
of the letter. For additional strength, a bead of
viscous cement such as ACRIFIX® 1S 0116 can be
applied to the perimeter of the letter.
Due to its formulation, ACRYLITE® LED sign grade
tends to absorb more solvent cement than
standard acrylic sheet. To compensate for this,
make sure to apply a liberal amount of cement to
the joint. This can be accomplished by tipping the
vertical piece about 1° so that more cement flows
into the joint. Alternatively, 0.002” shims can be
used to elevate the vertical piece slightly. Shims
should be removed after 45-60 seconds.
Initial setup time will vary between 5-60 seconds,
depending on the type of cement used and the
shop environment.
Guidelines
To achieve the best results when capillary
cementing with typical methylene chloride-based
solvent cements or cyanoacrylate based cements,
the following recommendations should be
followed:
• Insure a smooth, clean, low stress edge.
• Apply cement along the entire length of the
cement joint. Unlike with standard acrylic
sheet, the cement will not flow to the ends of
the cement joint if the application of cement
is started or finished more than ¼ - ½ from
the ends. Failure to fill the entire length of
the cement joint greatly reduces strength.
• Apply a generous amount of solvent cement to
Cementing
the surfaces being joined by: tipping the
vertical piece slightly so that its edge can
Acrylic to Acrylic Joints
accept more cement; using a larger diameter
Edge finished, jointed, or clean saw-cut edges will
applicator tip for increased cement flow; or
yield the best results. Avoid cementing sanded or
providing space at the joint by shimming
scraped edges because these operations tend to
(0.002- 0.004)
round the corners of the edge, leading to
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Joint set-up time will vary depending on the exact
the sheet can also cause adhesion problems.
formulation of the cement and the temperature
Therefore, it is important to remove dust and
and humidity of the cementing environment.
particles on the sheet surface by neutralizing
Cement joints made with ACRYLITE® LED sign
static charge using an ionized air gun. Leaving
grade will obtain initial soft strength
the masking on the sheet or using a removable
approximately 30 minutes after application of the
spray-on maskant may help to minimize
cement. They will begin to harden about 3 hours
exposure to overspray.
after cement application, but will not approach
full strength for 24 - 48 hours. As a general rule,
Painting
set-up time will be slightly longer than is
It is important to note that the overall impact
normally required with conventional acrylic sheet.
strength of a painted sheet may be lower than an
unpainted sheet. This is due to the lower impact
With cyanoacrylate-based cements, the chemical
strength and tensile strength of the paint itself.
reaction that hardens the cement joint is
The actual impact strength reduction will depend
triggered by moisture in the acrylic sheet and the
on the paint used.
atmosphere. Therefore, the rate of the curing
process is dependent on the rate at which
Vinyl Graphics
moisture in the air and in the sheet can diffuse to
The use of vinyl films for graphics and
the cement joint. Usually 48 hours is required for
backgrounds is highly recommended, no
the cement joint to reach full strength at which
reduction in garder impact.
point it will be as strong as the material itself.
Extra care should be taken when handling parts
Paint Removal
to avoid cement smudges. The resulting white
Spray and screen paints can be removed using
marks can usually be removed by wiping with
recommended paint removers. To reduce the
kerosene followed by rinsing with mild soap and
chances of crazing the surface of the sheet,
water.
minimize the amount of time ACRYLITE® LED sign
grade is in contact with these solvents. Even with
Painting Operations
the complete removal of paint from the surface of
ACRYLITE® LED sign grade sheet can be easily
the sheet, a phenomenon referred to as
painted and silk-screened using the same paints
“ghosting” often occurs. A hazy outline of the
and techniques as ACRYLITE® cast and extruded
original images may remain and become visible
products. However some paints, due to their
upon application of new paint.
brittleness, may result in lower overall impact
strength.
Thermoforming Operations
ACRYLITE® LED sign grade can be thermoformed
Surface Preparation
into a variety of finished parts and sign faces. Its
Paper masking may leave a latex residue on the
forming temperature range of 270-350°F offers
sheet. This residue can result in poor wetting of
faster cycle times than can be achieved with
the paint on the surface of the sheet and poor
conventional cell cast acrylic sheet. This wide
paint adhesion. If this is a problem, clean the
range of forming temperatures allows for greater
surface of the sheet prior to painting using a
versatility in thermoforming operations.
dilute mixture (50% or less) of isopropyl alcohol in
water. Rinse thoroughly with water and dry using
In most cases, excellent results can be achieved
a soft cloth or chamois. Particles on the surface of
using forming temperatures of 310-320°F. (Up to
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a draw ratio of 3:1) Parts that contain more detail
positioned approximately 2.5 to 3 inches above
or have a deep draw need to be formed at the
the sheet.
high end of the forming range, 320-350°F. Parts
should be left in the mold after forming until they
have reached a temperature of approximately
180°F. It is important to preheat the mold to
Time
Approximate
Approximate Temperature
120 seconds
260°F
180 seconds
310°F
210 seconds
350°F
approximately 160-180°F. If the mold is not
preheated, the formed part will cool too quickly,
resulting in internal stresses in the thermoformed
part. Draft angles of 2-3° will allow for easy part
removal.
Due to its method of manufacture, ACRYLITE®
LED sign grade will be oriented in the
manufacturing direction. Manufacturing direction
can be determined by looking at the label or
printed masking on the sheet. As you read the
label or masking, the manufacturing direction is
from top to bottom. The sheet may shrink up to a
maximum of 5% in the manufacturing direction
when heated. Be sure to allow for shrinkage when
Ideal thermoforming temperature is between 310 320°F. Many thermoformers judge readiness by the
sag and the feel of the sheet.
cutting blanks for thermoforming.
During the heating cycle, colorless ACRYLITE®
LED sign grade will turn a translucent white color.
After the sheet is formed and allowed to cool to
room temperature, it will regain its high light
transmission, losing its milky white appearance.
Forming Cycles
ACRYLITE® LED sign grade can be heated by a
variety of methods including infrared heaters,
circulating air ovens, and other conventional
heating methods. Generally, when heating
ACRYLITE® LED sign grade in an air circulating
oven, the heating times will be similar to
ACRYLITE® extruded. Heating cycles when using
Immediately after thermoforming, the sheet will
appear a milky white color. Cooling cycles can be
reduced by using cooling fans or applying
compressed air.
infrared heaters tend to be much shorter than
oven heating cycles.
The following table illustrates approximate
heating times for 0.118” (3 mm) ACRYLITE® LED
sign grade sheet. Testing was done on a
thermoformer equipped with ceramic heaters
The resulting sign will have excellent light
transmission, clarity and mold definition.
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It is important to note that actual times will vary
extruded acrylic sheet and much lower than line
for each individual thermoformer due to various
bending temperatures for cell cast acrylic sheet.
parameters such as the type of heater (convection
As a result, shorter cycle times can be expected
oven, radiation, etc.), distance from the sheet,
with ACRYLITE® LED sign grade. It is important
and single or dual side heating.
not to bend ACRYLITE® LED sign grade at
temperatures lower than 270°F because this leads
ACRYLITE® LED sign grade offers outstanding
to high internal stresses. These internal stresses
thermoforming definition at reduced cycle times,
can lead to crazing of the material should it come
compared to standard acrylic and polycarbonate
in contact with incompatible solvents or
sheet. The following graph illustrates its typical
aggressive chemicals.
performance.
As the temperature of the colorless ACRYLITE®
As can be seen from the graph, ACRYLITE® LED
LED sign grade rises, the material will turn a
sign grade sheet offers excellent part definitions
milky white color in the heated region. ACRYLITE®
at temperatures lower than those of conventional
LED sign grade will return to its original colorless,
cell-cast acrylic sheet and polycarbonate sheet.
high light transmitting state as it cools back down
to room temperature.
ACRYLITE® LED sign grade has a manufacturing
direction. This direction is identified by looking at
the masking label. As you read the ACRYLITE®
LED sign grade label from left to right, the
manufacturing direction will run from top to
bottom. On longer line bends, i.e. greater than 36
inches, a slight warp or bow across the sheet may
be evident. This effect can be reduced by
orienting the bend so that it is perpendicular to
the manufacturing direction.
ACRYLITE® LED
sign grade
Cell cast
acrylic sheet
Polycarbonate
sheet
Line Bending
ACRYLITE® LED sign grade can be easily line bent
using standard bending equipment. Line bending
should be performed when the core temperature
of the sheet is in the range of 270-290°F, which is
slightly lower than line bending temperatures for
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Trouble Shooting
Cutting Operations
Problem
Cause
Chipping
Solution
Excessive vibration
Ensure pieces are properly supported and clamped to working
Excessive blade run-out
Check blade collar, replace if run-out is greater than 0.002“
Improper blade height
Set blade height at 1/2” to 1” above work pieces
surface
For table saw cutting, use a triple-chip blade. (2.5 teeth per inch
Improper blade type
of circumference). For jigsaw cutting, use a wavy-set style blade
(8-13 teeth per inch)
Feed rate too fast
Melting
Decreased feet rate
Dull blade
Replace or sharpen blade
Feed rate too slow
Increase feed rate
For jigsaw cutting, use a wavy-style blade with 8 to 13 tpi. For all
Improper blade style
purpose table saw cutting, use a triple-chip, carbide tipped blade,
2.5 teeth per inch of circumference (i.e. 80 teeth for a 10 inch
diameter blade)
Drilling Operations
Problem
Cause
Solution
Chipping
Feed rate too fast
Use feed rates in the 3-12 ft/min range
Vibration
Ensure pieces are properly clamped to
Incorrect bit
For best results, use a “modified-for-
Blow Out
Insufficient back
Use backing material such as plywood or
support
acrylic
Melting
Feed rate too slow
Use moderate feed rates in 3-12 ft/min
Rotational speed too
Reduce rotational speed. RPM’s in the
high
500-1000 range will yield the best results
work surface
plastic” drill bit
range
Inadequate cooling
Use air or water mist
Incorrect bit
Use a “modified-for-plastic” drill bit.
Bit is not true
Replace bit
Smaller bits may require cooling
Bending Operations
Problem
Cause
Solution
Bowing from a
Uneven cooling of the
Make sure there is enough clearance to allow air
long bend
bend
circulation over the entire length of bend, including
the underside
Design a reverse “bow” in the cooling jig
Evonik Cyro LLC | ACRYLITE® LED | 2052C-0812-Cyro
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Routing Operations
Problem
Cause
Bit Breakage
Excessive heat buildup in bit due to Used compressed air to clear chips
Solution
inadequate chip removal
Plow routing using fast feed rates
Melting
Use bit designed for chip removal (twist up)
Reduce feed rate
Dull Bit
Replace or sharpen bit
Excessive load on bit
Make multiple passes
Feed rate is too slow
Use faster speed rates
Dull bit
Replace or sharpen bit
Inadequate heat removal
Use a larger diameter bit
Rotational speed too high
Reduce RPM’s. May need to be coupled with faster
Inadequate chip removal
Use a twist-up bit. Use a slow helix angle removal
Use a coolant such as air or mist
feed rate
rather than a fast helix angle
Consider multiple passes
Use compressed air to aid in chip removal
Chipping
Incorrect number of flutes on bit
Decrease number of flutes on bit
Feed rate too fast
Decrease feed rate
Vibration
Make sure pieces are adequately supported
Use a larger diameter bit and/or a bit with shorter
cutting length
Incorrect number of flutes in bit
Increase the number of flutes on the bit
Edge Finishing Operations
Problem
Cause
Solution
Dull edge after
Not enough heat/missed
Allow piece to cool, than make another, slower
flame polishing
spots
pass to cover these areas. Ensure the edge is fully
submersed in flame, but with minimum overspray
onto the sheet.
Charred edge after
polishing
flame poli
shing
Too much heat
Use MAPP or propane rather than
Hydrogen/Oxygen mixture. If MAPP gas is
unavailable and Hydrogen/Oxygen torch is used,
make sure flame is bright red/orange rather than
invisible blue
Dirt or contamination
Make sure edges of sheet are free from dirt or
Too much heat
See above recommendations
Rough edge
after buffing
Improper edge preparation
Make sure all tooling marks are removed by wet
Melting from edge
Feed rate too slow
Increase feed rate
Feed rate too fast
Reduce feed rate
contamination prior to flame polishing
Blisters on edge
after buffing
sanding edge finishing prior to buffing
finishing machine
Chipping from edge
finishing machine
Evonik Cyro LLC | ACRYLITE® LED | 2052C-0812-Cyro
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Cementing Operations
Problem
Cause
Solution
Crazing
Cementing flame polished or
Avoid cementing after these edge finishing steps
buffed edges
Bubbles
Uneven edges, allowing air to
Edge finish or rout edges prior to cementing
flow into gap
Premature weight application
Adjusting timing of weight application so that the
application of weights will not cause the cement to
flow out of the joint
Removing weights too soon
Allow longer cure time
Incorrect weights
Weights should be 1-2 lb per square inch of joint area
Cement applied too quickly
Make sure to stay behind the front of the cement
stream. This will prevent gaps from forming in the
joint
Weak joint
Insufficient cure time
Allow part to setup for at least 15 minutes before
moving and 24 hours before performing subsequent
fabrication steps
Not enough cement in joint
Use an applicator with a large diameter tip. Apply
cement slowly to ensure joint is completely filled with
cement. Tilt the piece slightly to allow cement to flow
into the joint. Scrape one side of edge to allow cement
to fill the joint better
Bad cement
Ensure cement is fresh and container is closed tightly
Humidity too high
Try another cement
when not in use
Hazy joints
Try to work in a less humid environment
Try adding acetic acid in small concentrations (3-5%)
to slow the rate of evaporation of the cement
Thermoforming Operations
Problem
Cause
Blistering
Surface temperature of Reduce heat time, oven
sheet is too high
Solution
Solution
temperature, or increase
distance from sheet to heaters
Inadequate part
Sheet temperature
For high definition parts, heat
definition
below optimum
to the higher end of the
forming temperature
forming temperature i.e. 320350°F
Painting Operations
Problem
Cause
Solution
Inadequate paint
Dust or other particles on
Remove particles prior to painting using an
adhesion
surface of sheet
ionized air gun
Improper paint mixture
Make sure mixture is at the right
proportions
Residue left on sheet from
Clean sheet using up to 50% IPA solution in
paper masking
water. Rinse thoroughly with water
Ghosting or hazing
Use of incompatible paint
If using paint removers, make sure to
effect
remover
minimize the contact time on the sheet
Crazing
Incorrect paint
See recommended source of supply in this
fabrication manual for approved paints.
Paint contacted sheet in
Make sure sheets are fabricated with
areas of high stress
minimum stresses
Evonik Cyro LLC | ACRYLITE® LED | 2052C-0812-Cyro
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Evonik Cyro LLC | ACRYLITE® LED sign grade | 2052C-0812-Cyro
Page 14/14
This information and all further technical advice is based on our present knowledge and experience. However, it implies no liability or
other legal responsibility on our part, including with regard to existing third party intellectual property rights, especially patent rights.
In particular, no warranty, whether expressed or implied, or guarantee of product properties in the legal sense is intended or implied.
We reserve the right to make any changes according to technical progress or further developments. The customer is not released from
the obligation to conduct careful inspection and testing of incoming goods. Performance of the product described herein should be
verified by testing, which should be carried out only by qualified experts in the sole responsibility of a customer. Reference to trade
names used by other companies is neither a recommendation, nor does it imply that similar products should be used.
Evonik Industries is a worldwide manufacturer of PMMA products sold under the ACRYLITE® trademark in the Americas and under the
PLEXIGLAS® trademark in the European, Asian, African, and Australian continents. ©Evonik Cyro LLC. All rights reserved.
Printed in the USA.
Evonik Cyro LLC
299 Jefferson Road, Parsippany, NJ 07054 US
Phone +1800 631 5384
www.acrylite.net www.acrylite-shop.com