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Acrylic reference.

The workhorse material of POP and fixture design, in one page: what each thickness is for, cast versus extruded, weight math for freight and install planning, fabrication notes, and a straight answer on recyclability.

Weight and sheet calculator.

Acrylic density is 1.19 g/cm3 (0.043 lb/cu in), about half the weight of glass at the same thickness. Enter part size and thickness for weight, and quantity for a run total.

Part length (in)

Part width (in)

Thickness

Parts in the run

Stock sheet size

Weight per part2.18 lb

Weight per sq ft at this thickness0.73 lb

Run weight109 lb (49.4 kg)

Parts per stock sheet (grid estimate)6

Sheets for the run9

Yield note: the sheet estimate is a straight grid with a 1/4 in kerf and edge allowance. Laser nesting on real jobs often beats it; router work with tabs and fixturing sometimes trails it. Use the material yield tool for spacing and grain-style constraints.

Fabrication quick notes.

Laser cuttingCast laser-cuts with a flame-polished edge; extruded edges can look slightly melted

Solvent cementingCapillary cement on clean square edges; extruded bonds slightly better

Line bendingStrip heat to roughly 300 F; inside radius of 2 to 3x thickness avoids stress marks

Cold bendingAvoid: minimum cold radius is about 180x thickness, and it invites crazing

Edge finishingScrape, sand through grits, then flame or buff polish for display edges

Thickness and application guide.

Starting points from retail and POP practice. Spans, loads, and lit applications should always be verified with a physical sample.

Thickness	Weight (lb / sq ft)	Best use in design
1/16 in	0.37	Face barriers, sign faces, laminating layers, small crafts
0.080 in	0.50	Vacuum-form stock, curved sign faces, literature pockets
1/8 in	0.73	The POP workhorse: risers, sign holders, small shelves, dividers, easels
3/16 in	1.10	Mid-size shelves and bins, brochure walls, larger sign panels
1/4 in	1.46	Fixture shelving, product platforms, hood displays, edge-lit panels
3/8 in	2.19	Heavy shelves, security cases, structural risers, premium bases
1/2 in	2.92	Countertop structures, load-bearing fixture parts, jewelry vitrines
3/4 in +	4.38+	Solid plinths, machined blocks, luxury display bases, water-clear edges

Cast vs extruded.

Property	Cast	Extruded
Cost	Higher	Lower
Thickness tolerance	Looser (to +/-15%)	Tight and consistent
Laser edge quality	Excellent, flame polished	Good, can melt slightly
Machining and polishing	Excellent	Gummier, can chip
Thermoforming	Wider working window	Narrower window, more sag
Solvent bonding	Good	Very good
Pick it for	Display work, machined parts, thick sections	Volume flat parts, vacuum forming, tight-gauge glazing

Recyclability, honestly.

Resin code#7 (Other)

Curbside recyclingNot accepted

Specialized recyclingYes, and improving

Acrylic (PMMA) is technically very recyclable: it can be reground for new sheet or depolymerized back to MMA monomer, and recycled-content sheet lines now exist from major producers. The practical catch is collection: as a #7 plastic it is not accepted in curbside programs, so recycling depends on fabricator scrap streams and takeback programs. For sustainability-driven briefs, spec recycled-content sheet, design for disassembly so acrylic components separate cleanly from corrugate and wood, and route production offcuts back through your fabricator. If the brief demands curbside-recyclable, acrylic is the wrong material; consider PET-based sheet and accept the optical tradeoff.

A few more designer facts: acrylic transmits about 92% of visible light, better than glass, which is why edge-lit panels work so well. It is UV stable outdoors for years without yellowing, unlike polycarbonate. It scratches more easily than glass, so spec hard-coat grades for high-touch retail surfaces. And it is brittle compared to polycarbonate: for impact-critical or security applications, polycarbonate wins; for clarity, flatness, and cost, acrylic wins.

Disclaimer: These tools were built at my desk to keep the answers I need in one place. I’m sharing them in the hope that they make your design process a little easier too. The math is checked against published standards and real-world experience, but specs change and materials vary. If you spot anything that seems off, please email me at donna@donnakadell.design and I’ll take a look.

Enjoy.