Betsy, Lexan, is the G.E. brand of Polycarbonate, another sheet plastic that is often used for windows etc. I believe it tends les to crack than might Plexi glass but I'd ask a plastics supplier what they thing.
both materials can be sanded or filed readilly. by touch it's pretty hard to tell the difference. How about something like Masonite? It often comes with one smooth side, and is probably much cheaper than plastic. It's a compressed wood/glue product. Tom
