Going Clear
After the mold is poured and layered, the next step is what separates ordinary acrylic from true Lucite: autoclave curing.
At Polaris, we use this pressure-and-heat process to turn every soft, opaque pour into a solid, crystal-clear award. And it’s not just for appearances — it ensures strength, clarity, and long-term stability.
Why Cure Under Pressure?
Lucite begins as a liquid monomer mix. As it starts to polymerize, heat is generated internally — a natural part of the chemical reaction. But that heat alone isn’t enough to create the optical quality clients expect.
Without pressure, bubbles form. Without temperature control, the material can crack, yellow, or under-cure. That’s why we use an industrial autoclave — a sealed, high-pressure chamber that allows us to control every variable.
The Autoclave Process at a Glance
Molds are placed inside a pressure vessel, usually stacked vertically
Nitrogen gas pressurizes the chamber to around 140 psi
The temperature is raised slowly, typically reaching 250–300°F
Curing lasts 8–10 hours, allowing full polymerization without trapped gas
This combination of heat and pressure drives out any microbubbles and allows the monomer molecules to fully link up, creating a high-molecular-weight acrylic block with exceptional clarity.
What Happens Inside?
The pressure keeps the monomer from boiling, even as temperatures climb
The heat completes the polymerization, locking in the shape and structure
Any embedded object must survive this environment — which is why we test in advance
The result is a solid piece of Lucite with no internal voids, no micro-cracking, and no cloudiness. Just smooth, crystal-clear acrylic ready for finishing.
Why It Matters
Many award suppliers don’t talk about this part of the process — because they don’t control it. But at Polaris, we understand the chemistry behind every piece. We've worked with these autoclaves, monitored curing cycles, and adapted materials for different curing profiles.
We know how a metal insert might overheat and how to prevent it. We know which plastics will warp or leach under pressure. That knowledge means fewer surprises — and better results.
This Is Where Clarity Comes From
A flawless Lucite award isn’t just about the design. It’s about execution — in chemistry, in timing, and in pressure.
And that pressure? We thrive under it.