Grace Under Pressure

What Is Cell-Cast Lucite, and Why Does It Matter?

If you've ever held a custom award that looked clear, precise, and jewel-like in finish — there's a good chance it was made from cell-cast Lucite.

At Polaris, we rely on this high-grade cast acrylic not because it’s the easiest option, but because it delivers the best results. Optical clarity. Dimensional depth. Long-term stability. These qualities matter when you're marking a major transaction, recognizing a milestone, or honoring a relationship.

So what exactly is Lucite, and how does it differ from the acrylic you might see in retail displays, photo frames, or off-the-shelf award blanks?

Cast vs. Extruded: Why It Matters

Most acrylic products you see every day — like Plexiglas sheets or injection-molded trophies — are made using mass-production methods like extrusion or molding. These methods are efficient for high-volume production, but they don’t offer the same material quality or flexibility.

Cell-cast Lucite is different. It starts as a liquid monomer, poured into molds in small batches. The material is slowly polymerized under controlled heat and pressure to eliminate bubbles and create a solid, optically clear block. This gives Lucite a more uniform structure and a higher molecular weight than extruded acrylic, resulting in:

• Greater optical clarity

• Better scratch resistance

• Improved polish and edge finish

• Higher durability and chemical resistance

It also allows for some of the most distinctive design features in the industry:

• Embedded items, like medical vials (common in pharmaceutical deal toys to mark FDA approval) or oil drops (popular in the energy sector for a first strike and other milestones) or even a custom cast metal piece

• Printing embedded inside the acrylic, rather than applied on the surface — often on clear film and set just beneath the surface, around 1/8" to 1/4" deep

• Surface etching for logos or text — since true 3D etching (internal laser etching) is only done in crystal, not Lucite

Why We Use It

Lucite is not the cheapest material. The process isn’t fast. And it certainly isn’t simple. Cell casting Lucite is a labor-intensive, highly specialized and complex process. But for one-of-a-kind awards and deal toys, the payoff is clear — in terms of clarity, quality, and customization.

It’s also lighter than crystal, which makes it more versatile for larger pieces or high-volume shipping — but no less precise. A well-finished Lucite piece can feel elegant and premium, even if it doesn’t have the same weight as a crystal award.

At Polaris, we use cell-cast Lucite because it allows us to create pieces that are both visually stunning and physically lasting. When you embed a real artifact inside a custom-shaped block and polish it to a high gloss, the result is something truly unique. It's not just a trophy — it's a moment, sealed in time.

The Polaris Difference

We’ve worked in Lucite factories. We’ve poured the molds, cured the material, cut the flash, and polished the surfaces ourselves. That hands-on experience is why we know what’s possible — and how to do it right.

We don’t outsource this knowledge. We bring it into every design conversation, every material selection, and every production decision. That’s how we make sure what you get from Polaris isn’t just custom in name — it’s custom in every detail.

Ready to Create a Piece That Lasts?

We design and produce custom awards and deal toys that capture the story of your achievement — and preserve it in crystal-clear Lucite.

Let’s get started — tell us about your project and we’ll make a symbol that is worthy of what it represents.