Cutting acrylic with a router requires careful technique to avoid cracking or melting the material. Here's a breakdown of the process, incorporating insights from provided information.
Acrylic Routing Techniques
Routing acrylic is a viable method for achieving precise cuts. The key is to manage heat buildup and minimize stress on the acrylic.
Step-by-Step Guide
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Preparation is Key: Secure the acrylic sheet firmly to a stable work surface to prevent vibration during cutting.
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Pilot Hole (Optional): If you're cutting out a shape from the center of the acrylic, drill a small hole in your acrylic equidistant from the edges. This provides a starting point for the router bit.
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Router Bit Selection: Use a straight edge router bit designed for plastics. These bits typically have a shallower cutting angle to reduce chipping and heat.
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Routing the Edges:
- If routing outside edges: Use a straight edge as a guide.
- Multiple Passes: Rout the outside edges with a straight edge router bit. Take multiple shallow passes rather than one deep cut. This prevents the bit from overheating and melting the acrylic.
- Flip if Necessary: I had to do it from one side first as the bit would only go a little over half-way into the acrylic, then I flipped the sheet over and cut the rest of the way. For thicker acrylic, you may need to cut partway through from one side, then flip the sheet and complete the cut from the other side, aligning the cuts carefully.
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Feed Rate: Maintain a slow and consistent feed rate. Rushing the cut will generate more heat and increase the risk of cracking.
Tips for Success
- Cooling: Consider using compressed air to cool the bit and the acrylic during cutting.
- Test Cuts: Practice on scrap pieces of acrylic to determine the optimal router speed and feed rate for your setup.
- Sharp Bits: Ensure your router bits are sharp. Dull bits create more friction and heat.
Summary
| Step | Description |
|---|---|
| Preparation | Secure the acrylic sheet. |
| Pilot Hole | Drill if needed for interior cuts. |
| Bit Choice | Use a straight edge router bit designed for plastics. |
| Routing | Multiple shallow passes with a guide, flipping if necessary. |
| Feed Rate | Slow and consistent. |
