Shaping Acrylic

[bigbanana]

Hi all
I've got an offiice chair in which the seat and the back are made from one L-shaped acrylic piece. The section is pink in colour and the acrylic is around 12mm thick.

One top corner of the acrylic chair back got damaged during a move yesterday and it's been suggested that the section is rounded off along with the opposite top corner to make it look the same.

My problem is, how do I do it. I first thought of getting a curved template to mark a curved shape on both top corners and the using a Dremel tool to shape them. Is this really feasible? What would be the best type of bit to fit into the Dremel to do the job? My fear is that excessive heat generated by friction during shaping might cause the acrylic to soften too much. Would a hand-file be a better choice?

Does anyone have any better suggestions? The thickness of the acrylic doesn't seem to make this an easy job.


Thanks.

[ACtheTROLL]

it depends how much needs to come off
12mm acrylic is serious cutting - I doubt a dremmel will do it unless you are polishing a very small part

couple of thoughts ... the template is good ... you'll end up with a 3 legged stool if you don't.

acrylic is soft and temperature sensitive.
dremmels are low power but high speed you'll have to be really careful

a router is high power and speed ... but you can get shaped cutters - so you get to chose the profile of the cut
gently gently and you'll get a consistent cut that's almost polished ... and with a follow bit ...(kitchen fitters use them to join corners of work surfaces) it will follow the template ... not cut through it

less accurate is the good old angle grinder - but they are made to shape, smooth and polish

[BillyBB]

You will need to keep the plastic cool whilst cutting. Do not use any power saw or dremel.
Try a router running at slow speed but you will need to make a guide, otherwise a hacksaw then file.

[bigbanana]

Thank you both. You've provided some sound advice. I'll think I'll keep the Dremel in it's case!