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Plexiglass, also known as acrylic or PMMA (polymethylmethacrylate), is one of the most commonly used materials in CNC milling. Due to its transparency, durability and relatively low cost, it is widely used in many industries. Plexiglass is still in high demand, from exhibition and retail equipment to signage, nameplates and decorative elements. Its versatility makes it one of the main materials in manufacturing, architecture and design, although proper processing of this material can be challenging. In this article, we will look at the recommendations for milling plexiglass and acrylic using a Wattsan CNC milling machine. We will talk about recommended tools, cutting parameters, and tips to help you achieve clean and accurate results without damaging the material.
Why is plexiglass a popular material for milling?
Plexiglass is often chosen for CNC milling because of its combination of external attractiveness and structural strength. It has a glass appearance, but is not brittle, which makes it ideal for both indoor and outdoor use. In addition, it is easy to shape, engrave and cut — provided that the correct processing methods are used. However, its fragility and tendency to melt when heated require special handling rules to avoid problems such as cracking, chipping or contamination of the tool.
Recommended tools and cutting strategy
When milling plexiglass, the choice of a tool is very important. We recommend using spiral or double-helical cutters specially designed for processing plastics. These tools ensure a clean cut and help to avoid chipping or overheating during the process.
When finishing, a cutting depth of 1-2 mm is recommended. When roughing, the cutting depth should not exceed 4 mm. Exceeding this limit increases the risk of material breakage or local melting. Acrylic is sensitive to both mechanical and thermal influences, so a conservative approach ensures better results.
As a result of careful testing, we have determined that the optimal feed rate for milling plexiglass ranges from 2000 to 2500 mm/min. With a higher feed rate, you risk damaging the milling cutter. Conversely, at a lower feed rate, the tool may generate excess heat, which leads to melting, darkening, or discoloration of the material at the cutting site.
Spindle and feed direction configuration
When working with plexiglass, the direction of rotation of the spindle relative to the rotation of the cutter is crucial. We recommend using a parallel flow setting, in which the milling cutter rotates parallel to the direction of movement of the spindle. This configuration improves surface quality and reduces the likelihood of roughness or tool marks.
As for the spindle speed, we recommend setting it in the range from 16,000 to 18,000 rpm. This range provides an optimal balance between cutting performance and temperature control. An air blowing or chip removal system is also very useful. The continuous air flow cools the cutting area and helps to remove the chips before they stick to the surface of the material again.
Visual quality control during milling
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When milling correctly, the plexiglass edge should look straight, clean, and without any chips or molten residue. A high-quality cut will not leave any marks on the tool. If you notice plastic residue sticking to the cutter, it means that the tool is either blunted or the cutting parameters are set incorrectly.
It is important to avoid using tools that were previously used for cutting hardwood, aluminum, or other non-ferrous metals. The cutters used to process such materials are likely blunted or worn, which can lead to poor results when processing delicate plastics such as acrylic.
Conclusion
Plexiglass milling on a Wattsan CNC milling machine allows for better results when using the right tools, speeds, and technologies. This material requires careful care due to its sensitivity to heat and mechanical stress, but it ensures precision due to its clean, polished surface, ideal for both different purposes. By following the above recommendations — using the appropriate milling cutters, maintaining optimal feed and spindle speeds, and ensuring proper cooling — you can achieve professional-quality results.
Whether you are manufacturing signage, product displays, or custom-made parts, mastering plexiglass milling techniques will expand your creative and technical capabilities with the Wattsan CNC router.
