Whole Lotta Lucite
There’s a whole lot that goes into every Lucite deal marker.
What seems like a simple clear block is actually the result of chemistry, timing, and practiced hands — and each step must be done exactly right. This is what we mean by small-batch, hand-cast manufacturing. Here’s how we do it.
Step 1: Mixing the Monomer and Polymer
The casting process begins with methyl methacrylate monomer — a crystal-clear liquid — and powdered PMMA polymer, which looks like fine white flour. The two are blended in precise ratios to create a viscous, pancake-batter-like mix.
Getting this ratio right is critical: it affects not just cure time, but clarity, hardness, and the presence (or absence) of bubbles. Skilled casters know when a mix needs adjustment based on the ambient temperature, the mold type, and the object being embedded.
Step 2: Mold Preparation
Each mold is custom-built for the award’s shape. For simple designs, we might use metal, acrylic, or even cardboard molds with a liner. More complex shapes use CNC-cut forms or 3D-printed shells.
We always cast oversized — by about 20–25% — because the material shrinks during curing. For example, a 4" x 6" x 2" award might start out closer to 5" x 7.5" x 2.5" to allow room for trimming and polishing.
Step 3: Layer Pouring and Gel Timing
Cell casting is typically done in layers, especially when embedding objects. Here’s how it works:
The first layer of acrylic is poured into the mold.
It’s left to partially polymerize into a gel-like state.
Then, the item (like a vial, coin, or printed film) is carefully placed.
A second pour covers the object.
Each layer appears opaque at first and gradually becomes clear as it cures. Working blind like this takes experience — we use jigs, measurements, and seasoned hands to position embedments accurately, even when we can’t see them.
More complex designs might involve 3–4 pours with items at different depths, requiring hours of timing and delicate placement.
Precision Every Step of the Way
Once poured, the mold is moved to the next phase: autoclave curing. But even before that, every aspect — from how thick the print film is, to where a vial sits, to how the corners are sealed — plays a role in the final result.
At Polaris, we’ve spent decades refining our methods, not just designing the award, but crafting it from the molecular level up. It’s what makes our pieces truly custom — and what ensures they arrive crystal-clear and celebration-ready.
Let’s Make It Right From the Start
Want an award that includes real objects, dimensional printing, or layered effects? Let’s talk. The best results come when the design and the casting plan are aligned from day one.