Routing Acrylic for templates?

[Resolve]

Hello!

I've made a few master template from MDF that I'm happy with. So much so I'd quite like to save the hassle of copying master templates and make them out of acrylic.

I can find sheets of acrylic the right thickness fairly cheap but I was wondering if it'sd a good idea to route acrylic with a standard 1/2" router?

What speeds/router cutters would be advisable for acrylic? I have a few template bits I would ideally use to just transfer my handmade shapes etc onto the acrylic..

 

[tnt423]

I've had good results from a standard Amana pattern bit. It was dull when I finished, so I may try a inexpensive bit next time. The chips will have a static charge and stick to everything, so clean up is kind of nasty.

 

[donepearce]

Hello!

I've made a few master template from MDF that I'm happy with. So much so I'd quite like to save the hassle of copying master templates and make them out of acrylic.

I can find sheets of acrylic the right thickness fairly cheap but I was wondering if it'sd a good idea to route acrylic with a standard 1/2" router?

What speeds/router cutters would be advisable for acrylic? I have a few template bits I would ideally use to just transfer my handmade shapes etc onto the acrylic..

Not too fast, make sure the cutter is cutting into the sheet, not out - or you will lose pieces. And lubricate with paraffin (kerosene).

 

[Kammo1]

As a rule the cutters for cutting plastic/acrylic are single fluted which mean only one cutting edge not 2 like standard cutters and speeds need to be tweaked to how fast or slow you move the router around to cut the template out. My guess is try on scrap and the cutters are paramount IMHO.

 

['59_Standard]

Look on the Trend site.

 

[SG Lou]

Another tip..........take very light cuts. It will lessen the chance of chip out and cracks. Ask me how i know ?

 

[BPW666]

What thickness acrylic sheet do people recommend using? I need to make up some pickup and bridge routing templates soon.

I came across this site looking for tips
Router Tutorial

 

[tnt423]

At least 1/2 inch or ~1.5 cm. I prefer 3/4 or ~2 cm. There is always a little gap between the cutter and the bearing so you need to make sure that is on the template until you get deep enough for the bearing to ride on the work surface.

 

[jonny]

Where do you get acrylic sheets that thick?

 

[Resolve]

Thanks guys! How do people reccomend lubricating the work area?

I'm going to buy a few cheap bits and have a practise on some scrap. I can just make copies onto MDF as working templates but having acrylic templates would be ideal.

 

[Jim_E]

Where do you get acrylic sheets that thick?

Laird Plastics for commercial buyers

or for small pieces retail; Online Plastics, Plastic Sheets, Plexiglass, Epoxy, Fiberglass, Carbon Fiber - Plastic World

 

[tnt423]

I got mine as salvage, just had to haul it.

 

[cmjohnson]

I've routed enough plexiglas, lexan, etc. for templates that I've learned what a bear it can be. Material that is intrinsically very tough is going to be tough to rout.

For outsides, I'd bandsaw as close to the desired shape as you dare to go, and then,
with less cutting required of the router, it goes pretty easy.

I recommend low RPMs to avoid melting, and slow feed rates, and small cuts, to make the process less stressful. It'll take longer but you won't fill up your trash can with
scrapped pieces if you take your time and go easy on the cutting forces.

I use a milling machine to do the internal cavity routs in my templates, except for
the fact that I usually dispense with the templates and just directly mill the routs
and cavities on the mill rather than use templates and a router.

There's always a certain amount of uncertainty and risk involved in using a router
and templates. I've had templates break while I was using them, and come
incredibly close to scrapping work that I had a lot of time invested in. I don't really
like that very much.