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I'm wanting to make some small-ish parts from 4mm acrylic, however I'm a bit apprehensive due to the tapered design and the radii.

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I have a selection of power tools in my arsenal, however a bandsaw isn't available. I do have a tablesaw, router, sander etc.

I think this is a 2 part question (sorry!):

  1. Would I risk cracking with this design? I'm aware that I might need to re-think the outer radii due to the "holes should be at least 1.5x the thickness away from the edge" rule.
  2. Can I use my sander to make the radii like you would typically see done with wood?
physicsboy
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1 Answers1

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In common room temperatures acrylic is brittle. It cracks easily if one tries to make a hole with an usual well sharpened drill bit. A worn drill bit works better. That's because acrylic loses its brittleness when warmed. In 100 degrees centigrade acrylic is plastic.

I do not know which stresses you are going to apply to your parts when they are in use. But you can avoid breaking them before they are fully fabricated. Try to make your parts in higher temperature. For example have a properly adjusted and aimed hot air blower. Keep it ON when you drill or make threads and a while before to warm the tools, too.

Experiments are a must!

user50879
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