Uploaded July 2025 | Updated September 2026, 2 days ago
In this episode of Make It Make Sense, we’re taking a deep dive into something most woodworkers overlook: the difference between cast and extruded acrylic. They might look the same on the shelf—but inside? They’re completely different animals.
We’ll break down how each one is made, why it matters for your jigs and fixtures, and test them in real-world shop conditions—table saw, bandsaw, drill press, and even mechanical stress. From internal tension to edge chipping, we’re not just comparing specs—we’re seeing how they behave under pressure.
If you’ve ever built a jig, template, or router base using acrylic…this one’s for you.
Along the way, I’ll use visual analogies (including colorful play-doh and pasta rollers) to explain molecular structure, manufacturing stress, and why some acrylic sheets chip and crack more than others. I’ll even walk through microscope footage to show what’s happening beneath the surface.
Whether you’re picking up plastic at the hardware store or ordering online, this is the information you need to make a smarter choice next time.
Watch this before you build your next jig.
If you're not interested in the full video, here's the summarized version → BS331: youtu.be/HRhesA18y6E
Check out the Acrylic Cast VS Extruded Microscope edition here → youtu.be/NHbSQP0KpUg
Check out my other channel! → @makethingswithrob
Used footage in this video 0:28-0:34 :
Creative Commons Use
@luggagemakingmachine-choaxu
youtu.be/PtNnUCfPpEk
My cast acrylic came from McMaster-Carr
My extruded acrylic came from an amazon retailer
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
William L McNally
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Marc B.
Richard B.
Make Things
#MakeThings #MIMS
In this episode of Make It Make Sense, we’re taking a deep dive into something most woodworkers overlook: the difference between cast and extruded acrylic. They might look the same on the shelf—but inside? They’re completely different animals.
We’ll break down how each one is made, why it matters for your jigs and fixtures, and test them in real-world shop conditions—table saw, bandsaw, drill press, and even mechanical stress. From internal tension to edge chipping, we’re not just comparing specs—we’re seeing how they behave under pressure.
If you’ve ever built a jig, template, or router base using acrylic…this one’s for you.
Along the way, I’ll use visual analogies (including colorful play-doh and pasta rollers) to explain molecular structure, manufacturing stress, and why some acrylic sheets chip and crack more than others. I’ll even walk through microscope footage to show what’s happening beneath the surface.
Whether you’re picking up plastic at the hardware store or ordering online, this is the information you need to make a smarter choice next time.
Watch this before you build your next jig.
If you're not interested in the full video, here's the summarized version → BS331: youtu.be/HRhesA18y6E
Check out the Acrylic Cast VS Extruded Microscope edition here → youtu.be/NHbSQP0KpUg
Check out my other channel! → @makethingswithrob
Used footage in this video 0:28-0:34 :
Creative Commons Use
@luggagemakingmachine-choaxu
youtu.be/PtNnUCfPpEk
My cast acrylic came from McMaster-Carr
My extruded acrylic came from an amazon retailer
Become a patron! → patreon.com/makethings ←
Huge thank you to my patrons that keep this thing going!
*MAKER TEAM*
Michelle B
Keith Current
William L McNally
Rich Lightfoot
Tutor the Barbarian
Aubrey G.
Nukebert
Sam W.
Aaron Knows DIY
G. Salazar
David B.
Marc B.
Richard B.
Make Things
#MakeThings #MIMS
