Lexan is polycarbonate resin thermoplastic. I've made a number of screens with various degrees of success. When it comes to drilling holes, I usually heat up an awl and lightly melt the holes after they are drilled. This seems to reduce cracking from the stressing of the drilling. Another cool thing about polycarbonate is that you can cut the thin stuff with tinsnips and clean up the edges with sandpaper. Makes prototyping quick and easy!

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William Fee
Iron Butt #26777
Tucson, Arizona