Sheet capacity

5 × 10 ft

AXYZ CNC router, vacuum hold-down

Materials

PC · PMMA · HDPE

Plus expanded PVC and ACM · 1/16 to 1/2 in

Minimum

One part

No tooling charge · $200 minimum order

Turnaround

1-day quote

Ships 5–10 business days after approval and payment

Instant-quote cutting services are excellent at small flat parts, and their size limits are honest: they are what fits their beds. The trouble starts with the parts engineers actually need large — a 36 × 60 in polycarbonate guard window, a 48 × 72 in lab splash shield, an infill panel for a T-slot frame that spans a whole machine.

Splitting that part into two pieces adds a seam, a joining strip and a weak line. Buying a full sheet and cutting it by hand gives you a track-saw edge and holes that never line up with the frame. The right answer is a router big enough to cut the part whole, from your file.

SendCutSend published limits

Router-cut polycarbonate and HDPE: 44 × 44 in, 46 × 46 in by custom quote. Laser-cut acrylic: 44 × 30 in. Polycarbonate thickness: 0.118–0.220 in.

Clearview

Parts from sheets up to 60 × 120 in, cut whole. 1/16 to 1/2 in stock; ask about thicker. A person reads your drawing before it is quoted.

Machine guard panels & windows

Polycarbonate panels for machine builders, integrators and maintenance departments: full-size guard windows, door panels, chip and splash panels, with fastener holes, hinge cutouts and slots routed to your drawing. We cut and finish the panel; the guard design and its compliance stay with the builder.

Infill panels for T-slot frames

Panels for 80/20-style inch and metric aluminum extrusion frames. Send the profile part number and the frame drawing; we size each panel to the clear opening plus the slot engagement on the profile maker’s data sheet, with corner reliefs, cable pass-throughs and access cutouts where you mark them.

Lab shields & splash barriers

Benchtop and floor-standing shields and splash partitions for labs and process areas, in polycarbonate for impact or acrylic for clarity. Glazing panels for framed partitions, kitted and labeled by panel number for the installer. Design and code compliance stay with the designer.

Covers, panels & wet-area parts

Equipment covers, access panels, back panels and wet-area panels in HDPE or expanded PVC, which shrug off water and do not rot, rust or delaminate. ACM where a part has to stay flat and light across a large span.

Fixture plates & production aids

Nest plates, assembly fixtures, kitting trays and drill templates routed from your CAD, so the fixture and the part come from the same geometry. Printed labels or part outlines on the plate when the fixture needs to explain itself.

One

Hold-down

A large thin sheet wants to lift off a vacuum table as the cut frees it, and a part that moves mid-cut is scrap. Thin polycarbonate holds down poorly, so we nest it with more spacing than the tightest layout, cut it in two passes, and tab small parts so nothing shifts. It costs a little sheet yield and saves the part.

Two

The right process for the material

Polycarbonate chars and yellows under a CO₂ laser, so it is always routed. Expanded PVC is never lasered: it releases hydrogen chloride. HDPE melts and is a fire risk on a laser. Acrylic can be laser-cut for a flame-polished edge within the laser’s 50 × 36 in bed, and is routed beyond it. Show edges get a slow, light final pass.

Three

Plastic moves with temperature

Acrylic and polycarbonate expand about 0.004–0.005 in per foot for every 10 °F; HDPE moves roughly two to three times that. A 10 ft polycarbonate panel grows about 1/4 in across a 50 °F swing. Tight round holes on a long panel crack at the fastener. We flag it on the quote and slot or oversize the holes where your drawing allows.

1  Send

DXF or dimensioned drawing, material and thickness, quantity, what the part mounts to, and where it ships.

2  Quote

One number for the finished part within a business day, with anything in the drawing that will not survive flagged before you order.

3  First article

On a production run, one part is cut and measured first. The tolerance we commit to is the one we measured on your geometry.

4  Ship

Masked, labeled by part number and packed flat or crated, with a packing list your receiving department can match to the order.

Geometry

A DXF at 1:1, with the units stated. Closed outlines, holes and cutouts on their own layers, countersinks and pockets called out with depth. A STEP model is welcome as a reference alongside it.

Critical dimensions

Mark the two or three dimensions that actually matter — the hole pattern that meets the frame, the edge that seats in the slot. We hold the drawing everywhere and check those on the first article.

Edges

Say which edges show. Machined edges are standard; a softened or sanded edge and flame-polished acrylic are priced upgrades. Polycarbonate is not polished before printing.

What is the largest plastic part you can cut?

The router takes sheets up to 5 × 10 ft (60 × 120 in), and a part can use nearly all of that sheet in one piece. In practice the limit on very large parts is shipping: anything over 108 in long, or over 165 in length plus girth (a 48 × 72 in panel already is), ships LTL freight on a crate rather than by parcel.

My part is too big for SendCutSend. Can you cut it?

Yes. SendCutSend publishes a 44 × 44 in limit for router-cut polycarbonate and HDPE (46 × 46 in by custom quote) and 44 × 30 in for laser-cut acrylic, as of October 2026. We cut parts from sheets up to 60 × 120 in. Send the same DXF you uploaded there and we will quote it within one business day.

What tolerance do you hold?

We state tolerance after measuring a first article on your geometry, not before. Plastic moves with temperature and large thin sheets behave differently from small thick ones, so a number quoted off a spec sheet would be a guess. Mark the dimensions that matter on the drawing and those are the ones we measure and report.

Can you laser-cut polycarbonate?

No. A CO₂ laser chars and yellows polycarbonate, so we route it. We also never laser expanded PVC or vinyl, because it releases hydrogen chloride, and we do not laser HDPE, which melts and is a fire risk. Acrylic is the plastic that lasers cleanly.

Should a machine guard be polycarbonate or acrylic?

Polycarbonate when anything can hit it: it is the impact material. Acrylic is stiffer, clearer and harder to scratch, but it cracks under impact. Check what the panel will be exposed to, because some cutting fluids and solvents attack polycarbonate. We cut and finish the panel to your drawing; the guard design and its compliance stay with the machine builder.

Can you make infill panels for an 80/20 or other T-slot frame?

Yes, in polycarbonate, acrylic, HDPE or ACM. Send the profile series or part number and the frame drawing. Each panel is sized to the clear opening plus the slot engagement from the profile maker’s data sheet, with cutouts where you mark them, and labeled by position so the frame goes together in order.

Can you print labels or graphics on the part?

Yes. A Mimaki UV flatbed prints CMYK on parts up to 98.4 × 51.2 in, registered to the cut from the same file. For an outdoor part we laminate over the print; Mimaki specifies a laminate or overcoat for this ink outdoors.

Do you take purchase orders?

Businesses pay by card or ACH when the order is placed, which most purchasing departments process like any other vendor; a W-9 is available on request. Government agencies and schools can order on a purchase order with net terms on orders of $3,000 or more.