How Is Aquarium Glass Made?
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Process One
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In many custom aquariums, the clear surface that allows viewers to enjoy tropical fish is actually not true glass, but is in fact acrylic. Acrylic material has several advantages over ordinary glass. While glass is usually found in only basic shapes, acrylic can be customized to accommodate creative designs. Acrylic is also more crack-resistant, and significantly lighter. These features make it an ideal material for large aquariums.
There are three main ways of manufacturing the acrylic sheets used in aquariums. The first is called "Continuous Casting." During this process, acrylic that has not yet completely polymerized is poured between two steel belts. These belts have a separation equal to the desired sheet thickness.
As the belts move, they carry the settling acrylic material past cooling mechanisms. These cure, or set, the acrylic as it moves, and produces perfectly flat sheets. Once at the end of the production line, the acrylic sheets are cut to the sizes necessary to construct the aquarium.
Process Two
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Another popular process used to manufacture aquarium acrylic sheets is called "Extrusion." During this process, plastic resin pellets are pushed into an extruder. This extruder heats the pellets, melting them together. The molten resin is then pushed into a die, which shapes the molten acrylic as it passes. The sheet is continuously fed through the extruder until it is the desired length, at which point it is cut into sheets.
Because large amounts of acrylic can be pushed through the extruder, this method is the most economical.
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Process Three
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The third method used to create acrylic aquarium sheets is called "Cell Casting." This technique uses a water bath to form the sheets. Liquid acrylic, called acrylic syrup, gets poured into a mold. This mold is sized and shaped according to the required design. Once filled with acrylic syrup, the mold is dropped into a bath containing water at a set temperature. As heat is removed, the acrylic cools into the shape of the mold.
All three of these acrylic techniques can be modified with the use of different molds. Because acrylic, like most plastics, is pliable when heated, warming the material and forcing it into shapes can create breathtaking aquarium displays that would be impossible with traditional glass.
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References
- Photo Credit Louis Hall
