[cryptodecals]

I've been cutting 3/16" acrylic letters ranging from 4" to 12" tall and using tabs to keep the pieces from coming loose.

I noticed however some times the tabs break, damaging the letters and/or cause piece to come lose and ruin the exit point.

What thickness do you recommend the tabs be and how thick? Also is there any suggestions for optimal placement?

I am using about 3-4 tabs per letter, generally one near the lead in and just 2-3 around the letter.

Using a 1/4" single o-flute up cut, 12000 RPM and 40 ipm. Cutting using a single pass with tab length of 1/4" and tab depth of 1/16".

Id appreciate any advice. Thanks in advance.

[JerryBurks]

Did you try double sided carpet tape (with fabric reinforcement) instead of the tabs? Your letters should be big enough to hold on that and removing the tape is probably much cleaner and easier than sanding of the tab remnants. The cut may also come out better without the bit going over the hump.

[cryptodecals]

Hey Jerry, I've tried double sided carpet tape and it works well. I mainly use the tape for smaller more detailed cuts. The reason I am trying to utilize tabs is to reduce the additional expense of the tape and labor in applying and removing it. Currently I use a chisel and rubber hammer to remove the tabs which has worked well. I use a laminate trimmer tool when necessary.

[tahustvedt]

Carpet tape works great for me as well. I use acrylic with protective film on both sides, and when I remove the protective film after cutting, the tape comes off with the film. It's much more stable than tabs if I take care to apply tape so that it holds the acrylic in strategic places. I usually cut small pieces of tape and stick them on the table before laying down the acrylic, which helps me find the critical spots by moving the spindle around.

[ssutton]

I cut acrylic a lot. I just came in from the shop after cutting 32 pieces of it. I use a vac hold down system and tabs for letters and other smaller parts. The key I think for me is that with vac hold down I have very little vibration of the parent material as it is being cut and I use a 2 flute upcut 1/8 inch bit at 40 IPM. The smaller bit seems to introduce less cut force and does not tend to dislodge the parts from the tabs. Your tab size seems TOO big for me. I typically use tabs that are 30% of the thickness of the material and about .075 long. I also cut with compressed air blowing at the bit so that I have no melting of the material.

Hope some of that helps.

Scott