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Cast vs. Extruded Acrylic: What’s Best for Sign Making?

When choosing the right type of acrylic for sign manufacturing, the decision often comes down to two types: cast acrylic and extruded acrylic. While they may look similar at first glance, the way they’re made – and how they behave – can make a big difference to your finished sign.  Here’s a breakdown of the key differences to help you choose the right material for your next project.

🔹 Manufacturing Process

  • Cast Acrylic
    Created by pouring liquid acrylic into moulds and allowing it to cure. This process results in a denser, more uniform material.

  • Extruded Acrylic
    Made by pushing acrylic resin through rollers to form sheets. This method allows for quicker production and slightly lower cost.

🔹 Thickness Tolerance

  • Cast Acrylic
    Thickness can vary slightly across a sheet – often by up to ±10%. This is usually not an issue for general signage but can affect precision applications.

  • Extruded Acrylic
    Offers much tighter thickness tolerances – typically ±5% – making it more consistent and predictable when machining or cutting.

🔹 Price Point

  • Extruded Acrylic
    Usually the more cost-effective option. Ideal for basic signage, protective screens, and budget-sensitive jobs.

  • Cast Acrylic
    Marginally more expensive due to the manufacturing process, but often worth it for premium finishes and higher durability.

🔹 Durability & Chemical Resistance

  • Cast Acrylic
    More resistant to cracking, crazing, and warping. It’s the better choice for applications involving:

    • Flame polishing

    • Exposure to cleaning chemicals

    • Stress-bearing installations

  • Extruded Acrylic
    More prone to stress-related cracking and surface crazing – especially if exposed to aggressive cleaning agents or tension during installation.

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🔹 Best Uses for Sign Makers

Application Type Recommended Acrylic Type Why?
Flame-polished Plauqes Cast Resists cracking during polishing
Illuminated panels / lightboxes Cast Excellent optical clarity, consistent lighting
Flat cut or 3D built-up letters Cast Resistant to UV wethering and temperature fluctuation
Budget sign panels / POS displays Extruded Lower cost and tighter thickness tolerance
Protective screens / temporary signs Extruded Ideal for quick turnaround jobs with lower material demands
 

✅ Quick Summary

  • Need premium finish, high durability, or flame-polished edges? Go with cast acrylic.

  • Need consistency in thickness or working to a tight budget? Choose extruded acrylic.

Both have their place in a sign maker’s toolkit – and knowing when to use each can make a big difference in both performance and price.

Looking for pre-cut or fabricated acrylic panels?
We offer both cast and extruded options, cut to size with quick turnaround. Get in touch for support on your next signage project.