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Acrylic Block: Methyl Methacrylate Syrup Cast in Layers between Glass
A thick acrylic block cannot be cast flawless in one pour. Tattersall (ICI, US 2,071,907, 1937) built it up in layers: pour 1/2 inch of syrup on a level glass plate, let it set for a day at room temperature, pour the next 1/2 inch on top, cover with a second glass plate, wait another day, then heat the sandwich at 80 °C. Each 1/2 inch layer shrinks to about 1/3 inch. The glass gives both faces a finished polish with no grinding.
The picture: our diagram.
Intermediate
3 days
Instructions
1
1
Level the bottom plate
Level the bottom plate
Set a glass plate on a ledge in a wooden frame, on a body of plaster of Paris, and level it carefully. The example sheet was 10 by 18 inches.
Tools needed:
Glass Pane
Wooden Frame
Plaster of Paris
Spirit Level 1.5m2
2
Pour the first 1/2 inch
Pour the first 1/2 inch
Pour room-temperature syrup 1/2 inch deep (about 1.5 litres for 10 by 18 inches; our figure). Cover against dust, but do not put the top plate on yet. Leave 24 hours at about 20 °C.
Materials for this step:
Methyl Methacrylate Syrup3 lTools needed:
Rubber Gloves
Thermometer - Lab3
3
Pour the next layer and cover
Pour the next layer and cover
Pour a second 1/2 inch layer on the first. Lower the top glass plate onto it so it rests on the syrup and keeps pressing on it. Leave another 24 hours at about 20 °C. For a thicker block repeat the layers, a day apart, and put the plate on the last one.
Tools needed:
Glass Pane4
4
Heat at 80 °C
Heat at 80 °C
Take the glass sandwich out of the frame and heat it for three hours at 80 °C to finish the polymerisation.
Tools needed:
Drying OvenThermometer - Lab
Heat-Resistant Gloves5
5
Spring off the glass
Spring off the glass
Spring the glass plates off the block with a knife blade. Both faces come out smooth and polished.
Tools needed:
Craft KnifeRubber GlovesMaterials
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Tools Required
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