Views: 0 Author: Site Editor Publish Time: 2025-11-11 Origin: Site
Not all acrylic sheets are created equal. Whether you're designing a high-end display case, manufacturing signage, or fabricating components for furniture or architecture, the type of acrylic sheet you choose can significantly affect the final result.
Here's a surprising fact: even though cast and extruded acrylic sheets look nearly identical to the untrained eye, their internal structure, manufacturing process, and performance differ in ways that matter.
So how do you know which one is right for your application? Should you pay more for cast acrylic, or will extruded acrylic do the job just as well?
In this post, you'll learn the key differences between cast and extruded acrylic sheets, including their manufacturing process, performance characteristics, typical applications, and cost. We'll also explore how to tell them apart, when to choose one over the other, and why working with a professional manufacturer like JUTU Technologies Ltd. can help you choose the best solution for your needs.
Cast acrylic sheets are made by pouring liquid MMA into molds, offering better optical clarity, superior chemical resistance, and a wider range of customization.
Extruded acrylic sheets are made by pushing acrylic resin through rollers, resulting in better thickness tolerance and lower cost, making them ideal for high-volume, budget-sensitive projects.
The ideal choice depends on your application, budget, processing, and visual requirements.
Choosing the right acrylic sheet can reduce waste, improve product quality, and optimize long-term performance.
Before diving into the differences, let's define what these two types of acrylic sheet really are.
Acrylic sheets, also known as Plexiglass, Perspex, or PMMA (Polymethyl Methacrylate), are transparent thermoplastic materials made from acrylic resin. They are widely used as a glass alternative for their superior light transmission, durability, and processability.
Acrylic sheets can be manufactured in two primary ways: casting and extrusion.
Cast acrylic sheets are produced by pouring liquid methyl methacrylate (MMA) into glass molds, where it undergoes chemical polymerization and solidifies into a rigid sheet.
Characteristics:
Each sheet is made individually, leading to minor thickness variations
Offers superior optical clarity with less internal stress
More resistant to chemicals and solvents
Excellent for laser cutting, CNC routing, and engraving
Available in a wider range of colors, finishes, and thicknesses
Extruded acrylic sheets are manufactured by pushing pre-polymerized acrylic pellets through a heated barrel and rollers to form continuous sheets.
Characteristics:
Thickness is more uniform and consistent
Lower internal stress but slightly lower optical quality
Less resistant to chemical solvents
More affordable and suitable for mass production
Performs well in vacuum forming and thermoforming
| Feature | Cast Acrylic Sheet | Extruded Acrylic Sheet |
|---|---|---|
| Manufacturing Process | Liquid monomer poured into molds | Melted acrylic pellets extruded through rollers |
| Optical Clarity | Excellent (ideal for displays and optics) | Good but slightly lower than cast |
| Thickness Tolerance | Less consistent (±10%) | Very consistent (±5%) |
| Surface Finish | Smooth and glossy | Slightly duller, may require polishing |
| Machinability | Excellent for laser, CNC, engraving | May melt or gum during laser cutting |
| Chemical Resistance | High (ideal for signage, lab equipment) | Moderate |
| Cost | Higher per square meter | Lower, better for budget-conscious projects |
| Color/Finish Availability | Wide range of colors, frosted, mirrored, etc. | More limited |
| Applications | Premium displays, awards, aquariums | Signage, lightboxes, general-purpose fabrication |
| Recyclability | Recyclable | Recyclable |
Cast acrylic is the premium choice for applications where optical performance, chemical resistance, or precision machining is vital. Here are scenarios when cast acrylic is your best bet:
High-end displays and signage that demand maximum clarity
Laser engraving or cutting projects requiring clean, smooth edges
Aquarium walls or architectural panels that need long-term durability
Medical or lab equipment exposed to chemicals
Custom furniture where aesthetics and edge finishing matter
Optical lenses or light diffusers, where light transmission is crucial
Projects requiring colors, textures, or thicknesses not available in extruded versions
Cast acrylic sheets offer up to 92% light transmission, are 10x more impact-resistant than glass, and are suitable for indoor and outdoor use thanks to their UV resistance.
Extruded acrylic is an excellent choice for mass production, cost-efficiency, and general-purpose use. You should choose extruded acrylic when:
You're working on budget-sensitive signage projects
You need high-volume material for fabrication or display
Your project requires uniform thickness (e.g., light diffusers, vacuum forming)
You're producing POP displays, store fixtures, or protective shields
Your fabrication process involves cutting, bending, or thermoforming
You need lower tooling costs and faster production cycles
Extruded acrylic is particularly suitable for industrial processes where cost and efficiency are priorities and optical perfection is not a must.
Let's break down the use of cast vs extruded acrylic sheets by industry:
| Industry | Preferred Acrylic Sheet Type | Reason |
|---|---|---|
| Retail & Display | Cast | High clarity, fine edge finish |
| Signage & Advertising | Extruded | Cost-effective and easy to fabricate |
| Furniture & Interiors | Cast | Better aesthetics, strong bonding |
| Lighting & Diffusers | Extruded | Superior uniform thickness for consistent light diffusion |
| Automotive & Transport | Cast | Impact resistance, optical clarity |
| Architecture | Cast | Durability, UV resistance, design flexibility |
| Medical & Laboratory | Cast | Chemical resistance, easy sterilization |
| Protective Barriers | Extruded | Mass production, transparency, affordability |
Cost is a major deciding factor for many buyers. Here's a breakdown:
| Cost Factor | Cast Acrylic | Extruded Acrylic |
|---|---|---|
| Material Cost | Higher | Lower |
| Tooling Cost | Higher (custom molds) | Lower (continuous process) |
| Fabrication Waste | Lower (cleaner cuts) | Higher (melting risk) |
| Customization Options | More | Limited |
| MOQ (Minimum Order) | Often higher | Lower |
| Per-Square-Meter Price | $2.5 - $5.0 | $1.5 - $3.5 |
Note: Prices vary by region, thickness, and finish. Contact JUTU Technologies for real-time quotes and bulk pricing.
Here are some practical methods to distinguish between the two:
Laser Cut Edge Test:
Cast acrylic produces frosted white edges
Extruded acrylic produces clear or melted edges
Thickness Test:
Cast sheets have minor variations
Extruded sheets are uniform
Solvent Test:
Cast acrylic resists cracking or crazing
Extruded sheets may develop hairline cracks
Price Check:
Cast acrylic is generally 20–40% more expensive
Label or Manufacturer Code:
Always request technical data sheets from your supplier
Choosing the right acrylic sheet supplier is just as important as choosing the material. Here's why global buyers choose JUTU Technologies Ltd.:
Full product line of cast and extruded acrylic sheets
Available in transparent, colored, frosted, glossy, and custom finishes
Sizes up to 2440×1220mm and thicknesses from 1mm to 20mm
Superior UV resistance, light transmission, and durability
OEM/ODM services for custom sizes, logos, and packaging
Export experience across Europe, Asia, Middle East, and North America
Contact JUTU at info@jutu.com.cn or call +86-21-3392 7425/26/27 for quotes, samples, or technical consultation.
Understanding the difference between cast and extruded acrylic sheets can save you time, money, and production headaches. Each type has its strengths—cast acrylic is ideal for high-precision, high-aesthetic projects, while extruded acrylic is perfect for large-scale, cost-sensitive applications.
The next time you're sourcing acrylic sheets, remember:
Start with your application requirements
Consider your budget and volume
Choose the right material type
Consult with a professional manufacturer like JUTU Technologies
With the right partner and the right product, you can turn your design vision into durable, high-performance reality.
A: Both are impact-resistant, but cast acrylic generally has better structural integrity and chemical resistance.
A: Technically yes, but cast acrylic provides cleaner cuts and less melting.
A: Yes, especially cast acrylic, which resists yellowing and fading in outdoor environments.
A: JUTU offers acrylic sheets from 1mm to 20mm thick. Custom options available.
A: Absolutely. JUTU provides transparent, colored, 10mm frosted acrylic sheets, and more.
