A DIY acrylic display case starts with the space inside the cover. Decide what the case must enclose, how you will reach it and which joints you can make accurately. Then prepare a panel drawing before ordering sheet material. This guide describes a simple open-bottom cover resting on a separate base; it is a fabrication guide, not a tested load-rated product plan.
1. Choose the construction before measuring panels
A bonded five-panel cover keeps the seams visually simple but is not designed to come apart. A mechanically joined cover can be serviced, although its holes and connectors need their own drawing. Choose one construction. Adding screws to a drawing made for bonded edges changes the joint, clearances and assembly sequence.
Acrylic, plexiglass and Perspex are common search terms for this project. Verify the actual sheet before buying: a familiar trade name does not establish the grade, coating or fabrication method.
2. Draw a panel layout from the clear internal space
Call the required clear width W, depth D, wall height H and sheet thickness t. In this particular layout, the front and back span the full outside width; both side panels fit between them. The top sits on all four vertical panels. The base is separate.
| Part | Quantity | Nominal geometry |
|---|---|---|
| Front and back | 2 | (W + 2t) × H |
| Left and right sides | 2 | D × H |
| Top | 1 | (W + 2t) × (D + 2t) |
These are geometric relationships, not finished shop dimensions. They assume ideal butt joints and exclude adhesive gaps, cutting tolerances, any base groove and movement allowances. A fabricator must adjust the drawing for the selected material and joint. A cover that enters a groove has less usable height than the nominal wall height.
3. Prepare the tools and the cut order
Prepare the approved sheet, a dimensioned drawing, measuring and squaring tools, a flat work surface, suitable supports and the joint-specific equipment. Buying accurately cut panels may be more useful than buying unfamiliar cutting tools for one project. Use the budget worksheet to compare the complete delivered cost of the different methods.
Use the sheet manufacturer’s cutting guidance and the tool manual. Do not assume that every thickness or coating can be scored and snapped. Keep mating edges identified so decorative finishing is not accidentally applied to bonding surfaces.
4. Dry-fit before making permanent joints
Lay out the parts in their final orientation. Check equal opposing panels, square corners and the position of the top. A gap that needs force to disappear is a drawing or preparation problem. Resolve it before adhesive or fasteners make the assembly permanent.
For a bonded acrylic construction, follow the exact adhesive’s preparation, ventilation, handling and cure instructions. ACRYLITE’s cementing manual warns against polishing edges that will be cemented. An attractive polished edge is not automatically a suitable bonding edge.
5. Fit the separate base and check access
The base supports the display object; the clear cover encloses it. Check the empty cover and base together before adding the object. Confirm that the cover can be lifted without scraping the contents or catching a shelf above. Do not use the top as a shelf or lift a loaded assembly by its transparent cover.
Questions before you cut
What acrylic thickness should I use?
It depends on panel span, support, joint and load. The different ACRYLITE thickness calculators illustrate why one universal thickness is inappropriate. A geometric cut list does not establish structural adequacy.
Can I use the same drawing for a large or wall-mounted case?
Those projects introduce different support and access requirements. Use the large-case design guide or wall-case design guide before choosing a construction. For a model-specific project, continue with DIY LEGO display case planning.
Sources and editorial method
Sources reviewed 15 October 2026. This article uses published documentation and original explanatory diagrams. It does not report a hands-on product test.
