Synthesis

PMMA is routinely produced by emulsion polymerization, solution polymerization, and bulk polymerization. Generally, radical initiation is used (including living polymerization methods), but anionic polymerization of PMMA can also be performed. To produce 1 kg (2.2 lb) of PMMA, about 2 kg (4.4 lb) of petroleum is needed.^{[citation needed]} PMMA produced by radical polymerization (all commercial PMMA) is atactic and completely amorphous.

Processing

The glass transition temperature (T_g) of atactic PMMA is 105 °C (221 °F). The T_g values of commercial grades of PMMA range from 85 to 165 °C (185 to 329 °F); the range is so wide because of the vast number of commercial compositions which are copolymers with co-monomers other than methyl methacrylate. PMMA is thus an organic glass at room temperature; i.e., it is below its T_g. The forming temperature starts at the glass transition temperature and goes up from there.^[15] All common molding processes may be used, including injection molding, compression molding, and extrusion. The highest quality PMMA sheets are produced by cell casting, but in this case, the polymerization and molding steps occur concurrently. The strength of the material is higher than molding grades owing to its extremely high molecular mass. Rubber toughening has been used to increase the toughness of PMMA owing to its brittle behavior in response to applied loads.