Three types of production process
Cell Cast Acrylic Sheets Production Process
Cell cast sheets are produced by assembling a mold for each individual sheet, and then pouring the acrylic materials into the mold with a funnel or other device. These molds, typically made of two large glass plates separated by a gasket the thickness of the desired material, are then placed into curing tanks, followed by being placed in a post-curing oven. The molds are then cooled, disassembled, and the sheets removed and inspected prior to masking.
Extruded Acrylic Sheets Production Process
Extruded Acrylic is manufactured on automated machinery which combines "pellets" of resin with acrylic monomer and catalyst, dispenses the mixture through a "die-block", runs it in semi-molten form through rollers which produce the final thickness, and finish or texture, and cuts and trims the sheets to their final size.
Continuous Cast Acrylic Sheets Production Process
Continuous Cast materials are also mass-produced, but don't utilize die-blocks or rollers. Essentially, big vats of Acrylic Monomer and catalyst are batch mixed and then poured onto highly polished stainless steel belts about 10'ft wide and 300'long and separated on the top and bottom by a space equal to the thickness of the material desired. These belts continuously convey material through a series of cooling and heating units to regulate the curing of the acrylic and saws at the end of the line cut the material "on the Fly" to it's final size.
Acrylic syrup is poured into a mold typically constructed from two tempered glass sheets separated to produce the desired thickness of the sheet and sealed with a gasket at the edge. The mold is submerged in a bath which maintains/controls a curing temperature and efficiently removes heat generated in the process when the monomer is converted to polymer.