Plastics & Acrylic Processing Encyclopedia
Welcome to the PlexiSystem knowledge base — a comprehensive, professionally curated resource on acrylic and plastics manufacturing. Whether you are an industrial designer, procurement specialist, architect, or product engineer, this encyclopedia provides technically accurate, production-ready information drawn from over a decade of hands-on manufacturing experience.
How to use this encyclopedia
Browse topics by category using the sidebar, or explore the sections below. Each article includes technical parameters, practical tips, comparison tables, and cross-references to related topics. All data is based on our production experience with materials from leading European suppliers. If you need help choosing the right material or technology for your project, start with the Material Guide or contact us directly.
Sections overview
- Materials — plastics profiles, properties, and selection guidance
- Processing Technologies — CNC, laser, bending, joining, finishing
- Product Categories — display cases, containers, organizers
- Practical Knowledge — standards, certifications, design guidelines
Materials
Understanding material properties is the foundation of every successful project. Our material guide covers the plastics we work with most frequently — from acrylic glass (PMMA) and PET-G to HIPS, foamed PVC (Forex), HPL laminates, and specialty acrylics. Each material profile includes mechanical properties, optical characteristics, chemical resistance, and machining recommendations.
Why material selection matters
The choice of plastic directly impacts every downstream process: cutting speed, bend radius, bonding method, finish quality, and long-term durability. A material that is easy to laser-cut (e.g. cast PMMA) may be difficult to thermoform, while a material with excellent impact resistance (e.g. polycarbonate) cannot be solvent-bonded with standard acrylic cements. Our Material Guide helps you navigate these trade-offs.
Material Guide
Comprehensive overview of PET-G, HIPS, foamed PVC (Forex), HPL, and specialty acrylics. Properties, applications, machining tips, and comparison tables with all key parameters.
Read the guide → MaterialsProcessing Technologies
From CNC routing to laser cutting, thermal bending to chemical bonding — each technology has specific capabilities, limitations, and optimal parameters. These articles provide the technical depth needed to make informed decisions about manufacturing methods. All parameters are based on our production settings with industrial-grade equipment.
CNC Machining
3-axis and 5-axis milling of plastics. Spindle speeds, feed rates, tool selection, chip evacuation, tolerances, and finish quality for PMMA, PET-G, PVC, and more.
Read the article → TechnologyLaser Cutting
CO2 and fibre laser cutting of plastics. Power settings, speed parameters, edge quality, material compatibility, polished edges on PMMA, and safety considerations for polycarbonate.
Read the article → TechnologyBending & Thermoforming
Line bending, kerf bending, oven forming, vacuum forming, and drape forming. Temperature ranges, cooling methods, minimum bend radii, stress whitening, and common defects.
Read the article → TechnologyJoining Techniques
Solvent cementing (dichloromethane), UV-cure adhesives, two-part epoxies and PU glues, ultrasonic welding, and mechanical fastening. Joint strength, optical clarity, and material compatibility.
Read the article → TechnologySurface Finishing
Flame polishing, diamond buffing, satin/matte texturing, spray painting, UV digital printing, sandblasting, and protective coatings. Quality comparison and cost analysis.
Read the article → TechnologyProduct Categories
Detailed guides on specific product types — from museum-grade display cases to industrial organizers. Each article covers design considerations, material selection, typical dimensions, production techniques, and ordering tips.
Display Cases & Showcases
Museum-grade UV-filtering cases, retail showcases, collector vitrines. Glass vs acrylic comparison, LED integration, climate control, and relevant conservation standards.
Read the article → ProductsContainers & Organizers
Gravity dispensers, desk organizers, industrial ESD-safe bins, and food-service containers compliant with EU Regulation 10/2011. Material selection and production techniques.
Read the article → ProductsPractical Knowledge
Standards, certifications, and design guidelines that ensure your project meets regulatory requirements and manufacturing constraints. Essential reading for anyone preparing files for production or specifying materials for regulated environments.
Standards & Certifications
IP ingress protection classes, fire rating norms (B1/B2, EN 13501), CE marking, food contact regulations (EU 10/2011), REACH/RoHS compliance, and museum conservation standards.
Read the article → ReferenceDesigner’s Guide
Practical handbook: dimensional tolerances, DXF file preparation, design rules for bending and gluing, colour options, minimum wall thicknesses, FAQ, and a complete ordering checklist.
Read the article → GuideKey Topics at a Glance
| Topic | Key materials covered | Primary audience |
|---|---|---|
| Material Guide | PET-G, HIPS, PVC foam, HPL, specialty PMMA | Designers, engineers, purchasing |
| CNC Machining | PMMA, PET-G, PC, PVC, HIPS | Manufacturing engineers |
| Laser Cutting | PMMA, PET-G, HIPS, wood, MDF | Production managers, designers |
| Bending & Thermoforming | PMMA, PET-G, HIPS, ABS, PC | Product designers, toolmakers |
| Joining Techniques | PMMA, PC, PET-G, ABS, PVC | Assembly engineers, designers |
| Surface Finishing | PMMA, PC, PET-G | Quality engineers, designers |
| Display Cases | PMMA (cast/extruded), UV-filtering PMMA | Museums, retail, collectors |
| Containers & Organizers | PMMA, PET-G, HIPS, PC | Retail, food service, industrial |
| Standards & Certifications | All plastics | Compliance officers, procurement |
| Designer’s Guide | All plastics | Designers, architects, engineers |
Important notice
The parameters and recommendations in this encyclopedia are based on PlexiSystem's production experience and should be treated as guidelines. Actual results may vary depending on specific material batches, equipment, environmental conditions, and operator skill. Always perform test cuts and trial assemblies before committing to full production runs, especially with new material suppliers or unfamiliar grades.
About PlexiSystem
PlexiSystem is a Polish manufacturer of custom acrylic and plastic products, operating since 2012. We specialise in CNC machining, laser cutting, bending, bonding, and finishing of engineering plastics. Our clients include retail chains, museums, industrial companies, and design studios across Europe. This encyclopedia reflects our practical, hands-on manufacturing knowledge — not theoretical textbook data.
Frequently Asked Questions
What is the difference between cast and extruded acrylic?
Cast acrylic (cell-cast PMMA) is produced by pouring liquid monomer between glass plates. It has tighter thickness tolerances, better optical clarity, superior laser-cut edge quality, and higher molecular weight. Extruded acrylic is cheaper and more uniform in thickness but has lower chemical resistance and tends to produce frosted edges when laser-cut. Read more in our Material Guide.
Can you cut polycarbonate with a laser?
Technically yes, but it is strongly discouraged. Polycarbonate produces toxic fumes (bisphenol A) when laser-cut, and the cut edge turns yellow-brown with poor quality. CNC routing is the recommended method for polycarbonate. See our Laser Cutting article for details.
What file format should I send for production?
We prefer 2D DXF files (AutoCAD 2018 or earlier) with curves converted to polylines. For 3D parts, STEP or IGES formats are accepted. See our Designer's Guide for complete file preparation instructions.
Do you ship internationally?
Yes. We regularly ship to EU countries and can arrange worldwide delivery for larger orders. Contact us for a shipping quote.
Quick links
- Glossary — definitions of technical terms used throughout the encyclopedia
- Material Comparison — side-by-side comparison of plastics properties
- Our products — browse the PlexiSystem product catalogue
- Portfolio — see our completed projects
- Contact — request a quote or ask a technical question