I’m working to create a line of high quality lighting fixtures out of semi complex geometric assemblies and have found a frustrating ammount of wiggle room when cutting with acrylic. An example of a design is such:
With so many connections before looping around, slight variations in the angle each pieces ends up resting at can create irregularities by the time assembly is done. I’ve done my best to qualify the effects of kerfing and get the slots to match nicely in the axis I’m cutting on, but the slots are squares and getting a perfect cube notch out of the material is tricky when the samples vary so much sheet to sheet. I’ve seen a spread of sized around a 1/32" wide which is a lot when each notch is only 1/8". Anyone have any materials suggestions?