Cast vs Extruded Acrylic

American Acrylics

An Analysis of Cast vs Extruded Acrylic


Acrylic, a versatile and widely used material, offers numerous applications in various industries. Two common types of acrylic used are cast acrylic and extruded acrylic. While both materials share similarities, they differ in terms of production methods, physical properties, and laser cutting and engraving abilities. Understanding these differences is crucial for selecting the appropriate acrylic material for specific applications. This article provides a comprehensive analysis of cast acrylic and extruded acrylic, shedding light on their unique characteristics and advantages.

Laser Cutting and Engraving Abilities 

Both cast acrylic and extruded acrylic can be laser cut and engraved, but they differ in terms of the results achieved and the process involved.

Laser Cutting:

Cast Acrylic: Cast acrylic is well-suited for laser cutting due to its excellent heat resistance and low melting point. It produces clean, precise cuts with smooth edges and minimal charring. The slower curing process contributes to reduced internal stresses, resulting in minimal distortion during laser cutting.

Extruded Acrylic: Extruded acrylic can also be laser cut effectively, but the process requires more precise control of laser parameters due to its slightly higher melting point. Improper laser settings may result in more charring and rougher edges compared to cast acrylic. However, with proper adjustments, extruded acrylic can still achieve satisfactory cutting results.

Laser Engraving:

Cast Acrylic: Cast acrylic is highly suitable for laser engraving due to its excellent clarity and consistent material composition. It produces crisp, detailed engravings with high contrast, making it ideal for applications such as personalized gifts, signage, and decorative elements.

Extruded Acrylic: Laser engraving on extruded acrylic is also possible but may yield slightly less detailed and contrasted engravings compared to cast acrylic. The slight variations in material composition and surface quality may result in reduced engraving precision. However, with proper laser settings, acceptable results can still be achieved.

Cast vs Extruded Acrylic Video


Production Methods

Cast Acrylic: Cast acrylic is manufactured through a cell-casting process, which involves pouring a liquid acrylic mixture into a mold and allowing it to cure. The liquid is made up of methyl methacrylate monomer, a catalyst, and other additives. This method allows for the creation of large, thick sheets with excellent clarity. The casting process provides the ability to incorporate dyes, pigments, and other materials to achieve a wide range of colors and effects. Additionally, cast acrylic sheets are less likely to have internal stresses and impurities due to the slow curing process, resulting in better optical properties.

Extruded Acrylic: Extruded acrylic is produced by forcing a heated acrylic mass through a die, which creates a continuous sheet. This method is suitable for manufacturing thinner and larger sheets compared to cast acrylic. The extrusion process involves melting acrylic pellets and continuously extruding them through the die. The resulting sheets have good surface finish and consistent thickness. However, the rapid cooling during extrusion can lead to internal stresses and slight variations in optical properties compared to cast acrylic.

Physical Properties 

Transparency and Clarity: 

Cast Acrylic: Cast acrylic sheets exhibit exceptional transparency and optical clarity, making them ideal for applications that require high visual quality, such as displays, signage, and optical lenses. The slow curing process reduces internal stresses, resulting in minimal distortion and excellent light transmission.

Extruded Acrylic: While extruded acrylic offers good transparency, it may have slightly lower optical clarity than cast acrylic due to the rapid cooling during the production process. However, it still provides satisfactory visual quality for many applications.

Impact Resistance:

Cast Acrylic: Cast acrylic sheets possess higher impact resistance compared to extruded acrylic. The slow curing process allows for the development of a denser molecular structure, enhancing the material’s toughness and ability to withstand impacts without shattering or cracking easily. This property makes cast acrylic suitable for applications that require durability and resistance to breakage, such as protective barriers and outdoor signage.

Extruded Acrylic: Although extruded acrylic is generally less impact-resistant than cast acrylic, it still offers sufficient durability for most applications. It can withstand moderate impacts without significant damage, making it suitable for indoor signage, point-of-purchase displays, and similar applications.

Thermal Stability:

Cast Acrylic: Cast acrylic has better thermal stability compared to extruded acrylic. It exhibits excellent resistance to high temperatures, retaining its shape and structural integrity without warping or melting. This property makes it suitable for applications that involve exposure to heat or require thermal stability, such as lighting fixtures and industrial equipment.

Extruded Acrylic: While extruded acrylic also offers good thermal stability, it may have slightly lower resistance to high temperatures compared to cast acrylic. Extreme heat can cause slight warping or deformation, making it less suitable for applications where thermal stability is a critical factor.


Cast acrylic and extruded acrylic offer unique characteristics and advantages that make them suitable for different applications. Cast acrylic’s slow-curing process results in excellent transparency, impact resistance, and thermal stability, making it ideal for applications requiring high visual quality and durability. Extruded acrylic, on the other hand, offers good transparency and satisfactory physical properties while being more cost-effective for large-scale projects. Both materials can be laser cut and engraved, with cast acrylic generally providing superior results due to its lower melting point and better optical clarity. Understanding these differences allows for informed material selection and ensures optimal performance in various applications.

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