Question 1

What's the difference between cast and extruded acrylic?

Accepted Answer

Cast acrylic laser-cuts and engraves better, leaving clean flame-polished edges and frosty white engraving, which is why it dominates sign, keychain, and earring blanks. Extruded acrylic is cheaper and more uniform in thickness but melts and chips under a laser and can gum up engraving. For CNC routing both work, though cast stays flatter. If a listing doesn't say which, message the maker before ordering for laser work.

Question 2

Which plastic is best for laser cutting?

Accepted Answer

Cast acrylic is the go-to for laser cutting, since it cuts crisp edges and engraves cleanly in thicknesses from 1/16" to 1/4". Two-color engraving plastic (laminate) is ideal for tags and badges. Never laser PVC or vinyl, as they release chlorine gas that damages machines and lungs. Look for sheet sold as laser-grade or pre-masked, which protects the surface from scorch marks during cutting.

Question 3

What plastic do I use for Kydex holsters or cosplay armor?

Accepted Answer

Kydex sheet, usually 0.060" to 0.093" thick, is the standard for holsters and knife sheaths because it thermoforms at low heat and holds a rigid shape. For larger cosplay armor, makers reach for thinner ABS or styrene sheet, which vacuum-forms over bucks. Both soften in a home oven or heat gun around 250-350°F. Buy 12"x12" or larger panels and order a spare, since first forming attempts often fail.

Question 4

How thick should craft plastic sheet be?

Accepted Answer

Match thickness to the use. Earring and keychain blanks work at 1/16" to 1/8" (about 2-3mm); standing signs and trophies use 1/4" to 1/2" for rigidity. Cutting boards in HDPE run 1/2" or thicker. Thermoforming stock like Kydex stays thin at 0.060"-0.093". Thicker sheet costs more and is harder to cut by hand, so buy the thinnest gauge that won't flex for your piece.

Question 5

How much does craft plastic cost?

Accepted Answer

Small blank and offcut packs typically run $6-$20, mid-size acrylic or HDPE sheets land at $20-$60, and large panels, full Kydex sheets, or bulk multipacks reach $60-$120 or more. Price tracks material, thickness, color, and size. Specialty stock like mirror, glitter, frosted, or two-color engraving acrylic costs more than clear or black. Compare price per sheet and per square foot across listings.

Question 6

How long do makers take to ship plastic stock?

Accepted Answer

In-stock sheets, blank packs, and standard colors usually ship in 3-7 business days. Custom-cut sizes, made-to-order shapes, and large or specialty-color orders typically take 1-2 weeks. Pre-masked and laser-grade sheet may be cut to order, so check the listing's processing time. If you need an exact size or a color match, message the maker before buying to confirm stock and lead time.

Plastic Sheet & Blanks for Crafting

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