Before & After

The Art of Finishing – From Dull Cast to Crystal Clear

Fresh out of the mold, Lucite doesn’t look like much.

It’s oversized. Matte. Slightly cloudy, almost opaque. It may have sharp edges, faint seam lines, or even excess material (called flash) from where the acrylic seeped into gaps during casting.

But that’s when master craftsmen begin to carefully transform each raw casting into a crystal-clear, polished piece of recognition. Here’s how it’s done.

Step 1: Trimming and Cutting

First, we trim off any excess material using precision saws and cutting tools. Because each piece is cast oversized to account for shrinkage, we cut it down to final dimensions — removing sprue marks (leftover marks from casting, generally appearing as small protrusions, lumps or rough patches on the surface of the Lucite — natural parts of the casting process that you’ll never see in a finished piece) and excess thickness.

Some pieces require straight cuts only, while others involve curved profiles or angled facets. We use band saws, diamond-tipped blades, or CNC tools depending on the shape and material.

Step 2: Sanding to Smooth

Next comes the sanding process — a gradual refinement of every surface:

• Coarse abrasives remove cutting marks and casting texture

• Medium grits refine flatness and eliminate haze

• Fine grits prep the piece for polishing

Most sanding is done by hand or using handheld machines, ensuring no corners are missed. Every face of the piece is worked individually to produce smooth, uniform edges.

Step 3: Buffing and Polishing

Using polishing wheels and compounds, we bring the acrylic to a high gloss. This stage is what gives Lucite its signature brilliance.

It’s a multi-pass process:

• Initial buffing removes micro-scratches

• Final polishing reveals optical clarity and deep reflection

• Corners and beveled edges are polished for visual and tactile smoothness

Step 4: Final Finishing

Once polished, any final enhancements are applied:

• UV printing or digital graphics on the surface

• Laser engraving of logos or text

• Color fill or painted details in recessed areas

• Mounting to a base, if applicable

We inspect every piece for clarity, accuracy, and alignment before packing — because by this stage, any noticable flaw would be unacceptable.

From Rough Cast to High Gloss

No Lucite award starts out looking like the finished product. It takes sanding, polishing, and real craftsmanship to bring the clarity forward.

And that clarity? It’s what makes a deal toy feel like more than plastic. It’s what elevates a recognition piece to something truly display-worthy.

At Polaris, this is our priority with every piece — so when it lands on a client’s desk, it looks exactly the way you imagined.