Bending plexi or lexan

[Brad Lee]

I need a piece to cover the front of my control panel, and I'm wondering how hard it is to bend either plexi or lexan. I'd prefer plexi cuz I can get it in tinted or black, but clear would work- then I could get some artwork underneath. I'm trying to avoid seams, ie taking 2 5"x24" pieces and using Lbrackets to join them

What I need is a 90' bend. If I took a piece that was 10"x24" and bent it longways(5" on each side of the L corner) it would be perfect

I've heard of bending with heat but lack tools other than lighters and hairdryers, and I don't really want to set my house on fire

[_Iz-]

Try warming it in the oven...

Might want to google that for the proper technique, I have heard of it being done that way...

[gajaman]

I remember bending some in school to make a photo frame, many years ago.

We had a tool that resembled an electric fire heater bar. Because the heating element is long and thin the heat is concentrated along the axis you want to bend.

I don't know how you could sfaely replicate this at home...

[shmokes]

yeah yeah....I remember that tool.  we used to make finger boards (miniature skateboards) and we'd use that to bend the sides up.  Never 90 degrees, more like 30, but 90 wouldn't have posed a problem.

[Brad Lee]

A lot fo the mod sites reccommend a heat gun like a paint stripper.. Dont think a hair dryer will put out that much. sigh

[rampy]

here's an old thread discussing the idea old thread and here's his follow up... thread hope you have better luck.. but soujnds like his overlay was several bends/complicated... *Shrug*

ymmv,

rampy

[Pixelhugger]

Once heated thoroughly plexi will bend with absolutely no resistance. 90' is no problem. You could probably bend it all the way back against itself. A blow dryer won't work - at least I'd be pretty surprised if it did. I've used a blow torch. The type of propane you buy in a aerosol sized can at Home Depot and fit with a brass nozzle also available there. Total cost is like $10.00 or so. I had never used a torch before but was bending plexi in minutes to make 2 aquariums to put inside old Macintoshes.

Be super careful NOT to heat to quickly or you'll get permanent tiny bubbles all over inside. Practice on scrap. And do it outside. To bend at 90' first place tin foil along a table edge (protect the hell out of the table if it's not a work bench)  Run the torch evenly back and forth along the edge - try to keep the flame off the plastic, though it'll take longer to bend. You can touch the plastic with the flame but not for long- and you increase the risk of bubbling. When you see the plexi start to bow, remove the torch and help it along. If you feel resistance keep running the torch. Do not try to rebend it once it has begun cooling.....it'll snap. It'll take a few minutes to cool completely. Go slow.

[paulkortne]

This is SO easy (i just found this out today)!  Lexan can bend all the way back to itself, and it doesn't even have "stretch" marks on the first bend!  I just bent it with my hands.  It has some resistance, but can be done.  Your 90 degree bend would be very sharp and look great.  Skrew plexiglass

It bends very sharply.  Maybe only a centimeter at most.
|
\|
     _______
   //
  ||
  ||
  ||

[Brad Lee]

But does it stay bent, or did you attach it to some kind of frame or shell?

This is whta I'm trying to cover- in a strange mix of 2D and 3D.

The blue line is the end dimension of my control panel- currently wood with lexan the same size
The green line is the side profile of whta I'd like to do with the plastic, kind of a wrap-around, as right now the front under my CP is wide open, and my cats like to go spelunking in the holes on either side


I think I'm gonna grab a 24x24 piece of lexan and one of my dummy CP pieces, put some braces in across the width so I have a solid edge to bend along and give it a try. Hopefully it'll be solid enough that I can remove the braces and jsut have the shell

[Psyklops]

I'm pretty sure I've read that Lexan (unlike Plexi) can be cold bent, meaning it doesn't require heating, just some elbow grease.

[paulkortne]

make sure to tell us how well it worked.  I'm currently thinking of doing somthing with bent lexan

[visciouslymamed]

Lexan is polycarbinate, same plastic used in CD's (my former job). It will bend very easily when it is warm. It will bend cold, but I don't reccomend it, especially for a 90 degree bend. Here's a few of things to keep in mind:

1. Don't heat too quickly or you will get air bubbles

2. Don't overcook / reheat or the poly will become very brittle

3. Keep heatgun about 6" away from the poly. Takes longer to heat but if it is too close the poly will start to burn (tint brown).

I would clamp the sheet down to the edge of a table (not the kitchen table ) along your bend (90 first, then the other). Heat from the top side and then gently press down to the desired angle. This should work out very well, just make sure to practice on a few test pieces. Let us know how it goes.

PS. Keep away from acetone!!!

[austinrfnd]

Hey, I saw your thread two days ago and I stumbled across this website.  I hope this helps:
http://www.wildreviews.com/G2

-Austin