Cutting & Finishing of 5-Inch Acrylic Protection Window

Heavy Equipment Safety Application

A contractor required a 5-inch-thick acrylic panel to be cut and finished for use as a transparent protection window mounted in front of an excavator operator’s cab. The panel, measuring 4 feet by 8 feet and weighing approximately 1,000 pounds, would serve as a primary safety barrier during excavation operations involving unexploded ordnance.

Because the material exceeded our standard CNC cutting capacity, the panel required a custom setup and handling approach. The customer supplied the acrylic without protective masking, so the sheet was first demasked, cleaned, polished, and re-masked to prevent surface damage during processing. Due to the panel’s size and weight, both sides were carefully handled, cleaned, polished, and re-masked as the sheet was flipped and repositioned.

To achieve the final dimensions without chipping or cracking, the panel was securely supported and cut in place using a large circular saw, allowing for controlled cutting of the oversized material. We then machined 1-inch radius corners on all four corners so the panel could slide safely into its steel mounting frame.

Why it worked:

• Custom setup enabled safe cutting beyond standard equipment limits

• Proper support and handling prevented cracking or chipping of thick acrylic

• Polishing and re-masking protected optical clarity during processing

• Fast turnaround allowed the contractor to meet transport and installation timelines

The finished panel was mounted into a steel frame positioned in front of the excavator cab, providing both clear visibility and critical operator protection.

Need oversized, high-thickness acrylic components cut and finished safely? Contact us to discuss your application.