| State-of-Art Acrylic Cell Casting |
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38,000 sq. ft plant designed & built in 2000 specifically for the manufacture of cell cast acrylic sheets. Employing the latest state-of-the-art technology to produce the world.s finest cell cast acrylic sheets. Computer aided manufacturing systems enable Acrylics USA to efficiently and economically produce short runs and quick turnaround. Acrylics USA is known for offering the industry the widest variety of special, custom and colored acrylic sheets. Welcome to the site where some of the industry.s highest performing acrylic sheets for an almost limitless number of applications at economical prices are made.
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| Reactor & Mix Control Room |
| The control console overlooks a separate .mix-room. where specially designed mixing and formulation tanks are housed. Monomer is mixed with a catalyst in a special steam heated reactor mixing tank. The mixture is then pumped into one of several special cooling/mix tanks where it is chilled, custom formulated, blended and mixed and held until it is ready to be used. All light fixtures, pumps and motors in the mix-room. are explosion-proof. |
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| Cell Filling Bay |
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The monomer solution, custom mixed and blended to meet the requirements of the finished sheet, is pumped into each cell (mold). Special racks that hold up to 40 cells are filled in this bay. Each cell consists of two pieces of tempered glass separated by a special gasket. The mold is held by torsion spring steel clamps designed to preset tensions. A specially built explosion proof pump is programmed to pump the precise amount of the blended material into each cell. The monomer mixture is triple filtered to remove any impurities. The final step is a vacuum evacuation of the cell where any air or bubbles are removed to insure the highest clarity sheet possible. |
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| What can we make for you today? |
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| Rack Inserted into Curing Oven |
| After all the cells in the rack are filled, the rack is positioned into one of six custom built curing ovens. There is only one rack for each oven. There is no community curing like most cell cast curing operations where an entire bank of racks, of all types, sizes and gauges of material are cured in one batch oven. By dedicating each oven to one type of sheet (size, thickness & performance specs), Acrylics USA can use computerized curing profiles that have been developed to match requirements unique to that type of sheet. Individual curing profiles insure that the best performing, fully cured sheet with highest clarity is produced. This extra, customized attention produces acrylic sheets that are the easiest, least costly sheet to machine and form. |
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| Six Individual Curing Ovens |
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Up to six individual racks (over 13,000 sq. ft./ 9+ tons) can be simultaneously cured in separate ovens The unique design enables each oven to run a custom and separate curing profile to exactly meet the requirements for the sheets in each rack/oven. These ovens are explosion-proof steam heated and cooled with high pressure/flow blowers so that the rate of heating and cooling is precisely metered and controlled. The unique design of the curing ovens insures that Acrylics USA sheets are fully and perfectly polymerized -- meaning better performing, stronger sheets that are easier to machine and form. |
| Automatic Cell & Sheet Handler |
| After curing the racks are moved to an automatic, custom-built station where the glass cells are machine opened, the acrylic sheet is removed, hand inspected and double masked. At this point the glass cells are cleaned and reconfigured with new gasket (which dictates the sheet thickness) for the next batch of material. |
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| Warehouse for Finished Sheets |
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The majority of Acrylics USA production is focused on making custom acrylic sheets to order. which we can turn around in as little as two days. However, we do stock a variety of sizes and types of sheets. |
| CNC Saws for Trim Requests |
| Most customers appreciate the better yield provided by Acrylics USA.s full sized, untrimmed sheets, Acrylics USA can trim sheets to any dimension on in-house CNC horizontal or a vertical panel saws. |
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| Packaging, Wrapping & Shipping |
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Acrylics USA ships pallet qty. sheets on made-to-order special pallets with super heavy stringers and top boards designed for 3,000+lbs. (76. x 101 1/2. sheets are shipped on pallets with four heavy duty stringers). Pallets are quadruple banded with corner protectors and mason board protects the bottom layer from damage. |
