I use acrylic a lot in my models, and cut it with a laminate blade in a
contractor saw - an old Delta that I got for free because it needed clean up
and a motor. The blade, a Freud, ran about 80 dollars as I recall. It makes a
decent cut that can be cleaned up fast with sanding blocks. Wet sanding using
wet/dry sandpaper keeps the dust down and the paper from clogging. If you use
the super fine papers - from 600 down to 2000 grit, available at automotive
paint supplies, you can get a glossy, clear finish that only needs a bit of
rubbing with polishing compound.
Routing also works with acrylic, cut creates a lot of dust. Slower speed
maching operations, like using a flycutter on a milling machine work very well
with acrylic. I use a stream of air from my compressor to help cool that bit
and keep the area clear.
One thing you don't want to do is aggressively feed the acrylic into a sander.
Even if it doesn't melt you will see some stress cracks develop, sometimes
after a considerable interval (days)
Hope this helps
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