It turns out Lexan (polycarbonate) is a really fun material to machine. Using blue painters tape to hold it to an MDF spill board makes it easy to machine a variety of complex shapes.

Lexan is a lot tougher than plexiglass, and won’t crack like plexiglass. However plexiglass does have better optical clarity and scratch resistance. But compared to plexiglass, Lexan is such a joy to work with.