Cast vs. Extruded Acrylic Sheets: Which One Fits Your Project Better?

If you’ve ever ordered acrylic sheets in bulk or worked on a precision-cut project, you’ve likely faced this question: should you go with cast or extruded acrylic?

At first glance, they look the same—clear, strong, and versatile. But dig deeper, and the difference lies in the details: how they’re made, how they perform under pressure, and how they respond to your specific application needs.

Let’s start with cast acrylic.

This type is produced by pouring liquid acrylic into molds, then allowing it to cure slowly. The result is a material that’s optically pure, highly rigid, and resistant to internal stress. For clients who need CNC-cut parts, deep engraving, or crystal-clear signage, cast acrylic is often the better option.

It’s especially well-suited for laser cutting, as it leaves behind clean, polished edges without much additional finishing. However, because it’s molded in sheets, its thickness can vary slightly—a factor worth considering in tight-tolerance work.

Now consider extruded acrylic.

This type is formed by pushing melted acrylic through rollers. The result is a sheet with highly consistent thickness and a more cost-effective production process. It’s easier to thermoform, making it ideal for bent panels, lightboxes, and applications that require heat bending or vacuum forming.

Extruded acrylic is often the preferred choice for high-volume production where precision can be balanced with efficiency. It’s also the go-to for customers who need sheet consistency over extreme clarity or edge detail.

So, which should you choose?

The answer depends on your priorities.
If you’re working on high-end displays, intricate machining, or need a more premium look and feel, cast acrylic will deliver.
If you’re scaling up production, prioritizing cost, or working with formed or bent components, extruded acrylic is likely a better match.

In short, it’s not about which one is better—it’s about choosing the right material for the right purpose.