Formed bracket
Line-bent · polished
Acrylic Bending & Thermoforming
Line bending for sharp angles, cold bending for large-radius curves, and thermoforming for domes and wrap guards — the right process for cost and optical quality.
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Thermally bent and polished clear acrylic bracket
Acrylic can be shaped three ways: line bending for localized angles, cold bending for large-radius curves, and thermoforming for domes, wraps and compound shapes. A cold-bend radius around 300 × thickness is a preliminary process range, not a universal minimum; sheet grade, thickness, temperature, edge condition, duration and geometry must be reviewed and may require a forming trial. Choosing the process affects tooling, cost and optical quality.
Equipment
| Heat (line) bending | 3 machines, length to 3000 mm — sharp angles: enclosures, covers, profiles |
| Cold bending | 4 stations — large-radius curves: architectural panels, curved barriers |
| Thermoforming | 2 ovens to 2000 × 1500 mm — domes, wrap-around guards, compound curves |
Heat forming
Localised heat · optical flats kept
Repeat formed parts
Controlled bend angle · polished edges
Process selection guide
Choosing the right process determines both cost and optical quality.
| Your geometry | Process | Notes |
|---|---|---|
| 90° box corner | Line bend | Crisp radius ≈ 2–3× thickness |
| Gentle curve, R > 300×t | Cold bend | No heat marks, best optics; springs into frame on site |
| Tight curve, R < 300×t | Thermoform | Formed over mold, stress-relieved |
| Dome / 3D wrap | Thermoform | Mold cost amortizes over quantity |
Bends combine with machining and bonding into finished assemblies.
Forming RFQ inputs
Send the material grade, sheet thickness, finished angle or 3D shape, inside radius, bend length, optical surface requirement, quantity and inspection requirements. Mark datum surfaces and any features that must align after forming.
Process controls
We review heating and forming sequence, grain or extrusion direction where relevant, fixture and support needs, and whether a first-piece review is required. Holes and critical features may be machined after forming so their positions reference the final shape; acceptance criteria are agreed on the drawing rather than implied by a general forming tolerance.
FAQ
What's the minimum bend radius for acrylic?
Use approximately 300 × thickness only as a preliminary cold-bending range. The selected sheet grade, thickness, temperature, edge quality and service condition can change the acceptable radius. Line-bend and thermoforming radii are reviewed from the geometry and may require a forming trial before production.
Does bending distort the material optically?
Line bends confine heat to the bend zone — flats stay optically perfect. Thermoforming can introduce slight thickness variation on deep draws; we quote expected optical quality per geometry.
Do formed parts need a mold? Who pays for it?
Line and cold bending need no mold. Thermoforming uses a mold — simple wood/aluminium molds are a one-time tooling charge and stored for your reorders.
Can you form and then machine the same part?
Yes, and it’s usually the right order: form first, then CNC-machine holes and edges in a fixture so features land accurately on the curved part — the 5-axis center exists for exactly this.
Get a forming quote
Send your part geometry for a free process recommendation.