I've been traveling and am coming into this late ... but my question is why
are you using Plexiglas? If you use Polycarbonate, you can bend it without
The ONLY disadvantage to polycarbonate over acrylic is that polycarbonate
surface will scratch much easier than acrylic. Acrylic, on the other hand,
will shatter when struck or bent, but is very hard to scratch (well,
compared to polycarbonate).
I was at a local machine shop the other month, and they were working
polycarbonate with their sheet metal working tools ... shear it, put a 90°
bend in it, mill it ... all without problems.