Acrylic One: A Safer Alternative to Fibreglass

by | Jun 1, 2026 | Resin

Replacing fibreglass with Acrylic One is becoming a major trend in the theming and prop industry. Today, many workshops are moving to safer, cleaner, and more environmentally responsible systems. Acrylic One (A1) is now a widely used alternative for film sets, architectural features, museums, theme parks, and sculptural applications. Acrylic One is replacing traditional fibreglass in theming because it is safer, water-based, low odour, and environmentally responsible.

Acrylic One fibreglass alternative

1. Comparison: A1 (Acrylic One) vs. Traditional Fibreglass

Traditional theming and prop fabrication historically utilized solvent-based polyester resins reinforced with glass fibres. Acrylic One (A1) represents a transition to water-based composite materials.

Many theming companies now use Acrylic One as a preferred fibreglass alternative for architectural features, props, and sculptural applications.

A1 Composition:

  • Liquid Component: Water-based acrylic resin.
  • Powder Component: Mineral-based filler.
  • Reinforcement: A1 Triaxial Fibre (glass fibre).

Polyester Fibreglass Composition:

  • Liquid Component: Solvent-based polyester resin (containing styrene).
  • Hardener: MEKP (Methyl Ethyl Ketone Peroxide).
  • Reinforcement: Chopped Strand Mat (CSM) or Woven Roving.

Primary Difference Factors:

  • Solvent Content: A1 is 100% water-based; Polyester is solvent-based.
  • Odour: A1 has negligible odour; Polyester emits high-intensity styrene fumes.
  • Safety: A1 is classified as non-toxic; Polyester requires significant PPE and extraction.

2. Occupational Health and Safety (OH&S) Profile

Theming workshops and on-site installations prioritize worker safety and environmental compliance. A1 functions as a non-toxic casting resin and laminating system.

Volatile Organic Compounds (VOCs):

  • A1: Ultra-low VOC emissions. Suitable for indoor application in museums, shopping centres, and sets.
  • Fibreglass: High VOC (Styrene). Requires explosion-proof extraction systems and specialized respirators.

Safety Specifications:

  • Skin Contact: Low irritation risk (water-washable).
  • Inhalation: No hazardous vapours.
  • Disposal: Brushes and tools clean with water; no hazardous solvent waste.
Acrylic 1 Mineral Powder and Liquid Resin, alternative to Fibreglass resin

3. Material Specifications and Performance Data

A1 provides a high weight-to-strength ratio, making it an efficient eco-friendly resin choice for large-scale theming projects.

Quantitative Data:

  • Density (Wet): 1.75 – 1.85 kg/dm³.
  • Density (Dry): 1.65 – 1.75 kg/dm³.
  • Hardness: 85 Shore D.
  • Compressive Strength: 30 N/mm².
  • Flexural Strength: 25 N/mm² (when reinforced with Triaxial Fibre).

Fire Resistance: A1 is inherently fire-resistant due to its mineral content.

  • Classification: B-s1, d0 (European standard EN 13501-1).
  • Performance: Does not contribute to fire spread; minimal smoke production; no flaming droplets.
  • European fire classification standard EN 13501-1 defines fire performance ratings for construction materials.https://en.wikipedia.org/wiki/EN_13501-1?utm_source=chatgpt.com

4. Compatibility with EPS (Expanded Polystyrene) Foam

A critical advantage in theming is the ability to apply a hard coat directly over carved foam.

Solvent Attack Data:

  • Polyester Resin: Styrene solvent dissolves EPS foam instantly upon contact. Requires a barrier coat (e.g., epoxy or plaster).
  • A1: Water-based chemistry. Zero reaction with EPS or XPS foam. Direct application is standard.

Process Comparison:

  1. Fibreglass Method: Carve Foam -> Apply Barrier Coat -> Cure -> Sand -> Apply Fibreglass -> Cure.
  2. A1 Method: Carve Foam -> Apply A1 with Triaxial Fibre -> Cure.
Acrylic One fibreglass alternative for architectural mouldings

5. Structural Reinforcement: A1 Triaxial Fibre

While polyester fibreglass uses Chopped Strand Mat (CSM), A1 utilizes A1 Triaxial Fibre for optimal structural integrity.

Acrylic One continues to grow as a safer and preferred alternative to Fibreglass, for Architectural Features, Props, and sculptural applications.

Replacing fibreglass with Acrylic One allows workshops to achieve safer fabrication methods while maintaining high structural strength and excellent surface quality.

Reinforcement Specifications:

  • Fibre Type: E-glass.
  • Structure: Non-preg triaxial weave (multi-directional strength).
  • Weight: 160g/m².
  • Benefit: Allows for thin-walled, high-strength laminates (typically 3mm – 5mm thick).

Application Variables:

  • Lamination: Layer 1 (A1 Base) -> Layer 2 (Triaxial Fibre) -> Layer 3 (A1 Base).
  • Quantity: Typically 2 to 4 layers of Triaxial Fibre for structural theming skins.
Acrylic 1 Triaxial Fibre reinforcement roll showing open-weave structure, replacing Fibreglass matt

6. Pigmentation and Surface Finishing

A1 is a versatile composite material that accepts high loading of pigments and fillers to replicate natural materials (stone, wood, metal).

Pigmentation Ratios:

  • Standard Dosage: 2% by weight of the total mix.
  • Maximum Dosage: 5% by weight.
  • Available Palette: Black, White, Red, Blue, Yellow, Ochre, Terracotta, Green.

Surface Additives:

  • Metal Powders: Bronze, Copper, Iron for cold-casting.
  • Fillers: Sand, stone dust, or marble flour for texture.
  • Sealers: A1 Sealer (Matte or Gloss) for UV protection and water resistance.
A1 Pigments in assorted colours for resin colouring of Acrylic One resin

7. Technical Application Steps for Theming

The following protocol defines the standard lamination process for creating lightweight, durable props and sets.

Step 1: Preparation

  • Clean foam surface or mould.
  • Ensure ambient temperature is between 10°C and 30°C.

Step 2: Mixing

  • Ratio: 2 parts A1 Powder to 1 part A1 Liquid (by weight).
  • Procedure: Add powder to liquid. Mix for 1 minute using an A1 Mixing Blade until smooth.

Step 3: Base Coat (Beauty Coat)

  • Apply a thin layer (1mm) of unreinforced A1 to the surface.
  • Use a brush or spatula to capture detail.

Step 4: Lamination

  • While the base coat is wet/tacky, apply a layer of A1 Triaxial Fibre.
  • Brush A1 mix through the fibre to ensure full saturation.
  • Repeat for additional layers as required by structural needs.

Step 5: Curing

  • Working Time: 20 – 25 minutes.
  • Initial Cure: 60 – 90 minutes.
  • Full Strength: 7 – 28 days (depending on humidity and temperature).

Step 6: Finishing

  • Sand surface (if required).
  • Apply A1 Sealer to protect against moisture and UV degradation.

8. Control Additives

To manage production schedules in Australian climates, specific additives are utilized:

  • A1 Accelerator: Reduces curing time. Recommended for cold environments.
  • A1 Retarder: Extends working time. Essential for large-scale laminations or high-temperature conditions.
  • A1 Thix A: Increases viscosity for vertical applications (prevents sagging).

9. Procurement: Active Composites (Australia & NZ)

Australia Composite Solutions is the primary supplier for A1 Acrylic One systems in the Australian and New Zealand markets.

Acrylic One continues to grow as a safer fibreglass alternative for modern fabrication workshops.

Service Scope:

  • Inventory: Full range of A1 Base Material, Pigments, Sealer, and Reinforcements.
  • Distribution: Shipping available to major hubs including Sydney, Melbourne, Brisbane, Perth, and Adelaide.
  • Technical Support: Consultation for large-scale theming and architectural projects.

Product Availability:

  • Small Scale: 1.5kg and 7.5kg kits.
  • Professional Scale: 15kg and 60kg kits.
  • Industrial Scale: 1000kg+ bulk orders.

Recommended Acrylic One Products

Remember Acrylic One is replacing Fibreglass in theming

For many workshops, Acrylic One has become the safer alternative to fibreglass because of its low odour, water-based chemistry and professional finish quality.