Bending and forming Plexiglas®: Practical guide to thermoforming

Plexiglas® (also known as acrylic glass or PMMA) is one of the most versatile plastics used in sign making, shopfitting, and interior design. A key advantage: Under controlled heat, the material can be molded into almost any shape—without losing its transparency or stability.

In this article we show you how to heat, bend and cool Plexiglas correctly and give practical tips for a clean result

1. Why thermoform Plexiglas?

• Lightweight but very robust material

• High light transmittance (up to 92%)

• Can be made into many shapes without losing its optical properties

• Ideal for displays, protective covers, menu holders or illuminated advertising

2. What tools do you need?

To process Plexiglas safely and precisely, we recommend:

• Infrared heater or hot air gun for targeted heating

• Heating rails or bending devices for straight edges

• Form templates made of wood or metal for curves and special shapes

• Weights or clamps for fixing during cooling

• Protective equipment : heat-resistant gloves and safety goggles

3. Step-by-step instructions

Step 1: Heat

• Heat Plexiglas evenly to 150–170 °C until it becomes flexible

• Avoid overheating to prevent blisters or stress cracks

Step 2: Shapes

Carefully place the plate over the desired shape or clamp it into the bending device

• Apply even pressure until the desired curvature is achieved

Step 3: Cool down

• Keep material fixed until it is completely cured

• It is best to cool down slowly – too rapid cooling (e.g. with cold air) can create tension

4. Professional tips for perfect results

• Remove protective film only after processing to avoid scratches

• For precise bending radii (e.g. for A4 or A5 displays) a professional bending machine is recommended

• For series production, it is worthwhile to invest in industrial thermoforming systems that save time and material

5. Typical application examples

• Individual sales and presentation displays

• POS materials and exhibition stands

• Menu card holders and information stands

• Protective hoods and covers in furniture and mechanical engineering

Conclusion

Bending and shaping Plexiglas isn't rocket science—if you maintain the right temperatures, use the right tools, and have patience while it cools down.

👉 In the Spy Media GmbH workshop we use these techniques every day to produce customized plexiglass products for our customers in Germany and Europe.