An acrylic keychain is a 50 mm part that has to survive a pocket, a bag and a set of keys, and most failures trace back to two decisions made before cutting: sheet thickness and how much material sits around the ring hole.
A promotional supplier ordered 12 000 blanks in 3 mm with a 4 mm hole set 2.5 mm from the edge. Nine percent broke at the hole within a month, all in the same corner of the outline.
Acrylic keychain blank thickness and hole detail
- Promotional blank: 3 mm
- Retail item: 4 to 5 mm
- Hole: 4 mm diameter, 4 to 5 mm edge distance
- Outline: 3 mm minimum wall anywhere
The hole is a stress point, not a hole. Material around it carries the whole load of a swinging keyring, and a narrow arm on a decorative outline is where it tears.
Cutting, edge polish and print
Laser cutting gives the tightest outline and a frosted edge; a quick flame pass clears it but shrinks the profile if the operator lingers. Router cutting on 5 mm leaves a machined edge that polishes to optical clarity and holds dimension better on large runs.
Printing belongs before or after cutting depending on process: UV print on the cut blank needs a jig to keep registration, reverse print on clear stock is protected by the material but shows through in mirror.
For blank sourcing in sheet form, acrylic cut to size service covers the tolerance side.
Send your artwork, finished size and run quantity to oversales@rpplexiglass.com for keychain blank pricing.
Frequently Asked Questions
What thickness acrylic keychain blank?
3 mm for a promotional blank, 4 to 5 mm for a sold retail item that takes daily pocket wear. Below 3 mm the ring hole has too little material around it and cracks.
Laser or router for keychain blanks?
Laser for fine detail and small runs, router for thick blanks and quantities where a polished edge is wanted. A laser leaves a slightly frosted edge that needs flame polishing to look clear.
How far should the ring hole sit from the edge?
At least 4 mm of solid material between hole and edge on 3 mm stock, 5 mm on 5 mm stock. Closer than that and the blank fails at the hole under a keyring load.