I’m preparing to cut out 4 24"x24" sheets of 3/8" polycarbonate (lexan) to make ~180 coat hooks for our youth organization. If it were acrylic, I’d do this on our 100w laser, but the lexan is a big no-no there as it likes to melt (then catch fire) instead of sublimate.
Anyone have advice on setting up this project as I’d rather not screw-up stock if I can avoid it.
A layout is below - there is .34" between pieces (each piece is 1.5"x7"). I’m debating 1/4" vs 1/8" single flute endmill for the cutouts (1/8 is needed for the screw holes).
Probably will go full tape & glue for workholding all these these small parts. I also thought about cutting all the holes first and screwing them all down, but 90 screws would be a pain. If I use an 1/8", I’m not sure that tabs would be helpful as so little stock would be remaining, but am interested in any advice.