Acrylic sheet is commonly manufactured using one of three techniques.

Extruded Acrylic Sheet
Continuous Cast Acrylic Sheet
Cell Cast Acrylic Sheet

Extruded Acrylic Sheet
Extrusion is a continuous production method of manufacturing acrylic sheet. In the extrusion process, pellets of resins are fed into an extruder, which heats them until they are a molten mass. This mass is then forced through a die as a molten sheet, the spacing of which determines the thickness of the sheet and in some cases the surface finish. The continuous band of sheet may then be cut or trimmed into its final size.

The final product offers much closer thickness tolerances than cast sheet and due to the volume at which extruded sheet is produced, it is the most economical form. It's available in a wide selection of colors, finishes and sizes.

Continuous Cast Acrylic Sheet
Continuous Casting is also a mass production form for manufacturing acrylic sheet. The process involves pouring partially polymerized acrylic between two stainless steel belts, which are separated by a space equal to the thickness of the sheet. The belts move through a series of cooling and heating units to regulate the curing and the sheet is cut at the end of the production line.

Cell Cast Acrylic Sheet
Cell Casting uses any of three processes. The first is the water bath technique. Acrylic syrup is poured into a mold constructed from two, tempered glass sheets, which are separated to produce the desired thickness, then sealed with a gasket. The mold is submerged in a bath, which maintains the curing temperature and efficiently removes the heat generated in the process.

The second casting technique includes the original process which involved placing the "molds" containing a "syrup" in a circulating air oven in which air passes, at a moderately high velocity, over the surface of the mold.

The third method involves the use of a piece of equipment similar to a plate and frame filter press. Sections, which serve as the mold for the sheet, are alternately configured with sections through which water is circulated to promote the polymerization and cure of the sheet.

All Cell Cast sheet products should go through a "post-cure" or "annealing" process.

Extruded sheet is by far the most uniform, economical, and is offered in a variety of colors, finishes and thicknesses.