How to Cut Lexan

Lexan, a durable thermoplastic, is relatively easy to cut and, in fact, may be cut in two different ways. It is advisable to make practice cuts on sections of Lexan that will not be used in order to determine which method works best for your particular situation. While it is possible to cut Lexan with a table saw or even a jig saw, the best saw by far for cutting Lexan is a band saw. The blade on the band saw tends to stay much cooler than with a table saw or a jig saw. The real trick is in learning the proper speed to move the blade through the material. If the blade-speed is too fast, you may cause chips and even crack the material you are cutting. Cutting too slowly can result in the build-up of too much heat and the consequent burning and melting of the Lexan along the cut-line, resulting in an uneven and often unsightly cut.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Band saw
• Masking tape
• Eye protection
• Gloves
• 100-grit sandpaper
• Straight edge
• Utility knife

1. Cover both side of the Lexan piece with masking tape where the cut will be. The tape helps prevent chipping. Mark your cut-line on the masking tape.

2. Use a medium-toothed blade, such as a 3TPI blade rather than a fine-toothed blade on your band saw. A fine-toothed blade tends to clog and burn the Lexan.

3. Push the Lexan through the blade at a constant speed. Do not push so fast that there is a great deal of resistance, as this can cause chipping and even cracking of the Lexan. Do not push so slowly that the blade begins to overheat and cause scorching on the plastic or causes the plastic to melt and re-solidify behind the blade as it cuts.

4. Sandpaper the edges of your cut Lexan with 100-grit paper to smooth any irregularities and to taper any sharp edges.

5. Cover both sides of 1/4 inch thick or less Lexan with masking tape as per Step 1 and mark your cut line if you do not want to use a band saw. Lay a straight edge along the line and use a utility knife to score the plastic. Your score should be deep, close to one half the thickness of the piece you are cutting.

6. Lay the scored line along the edge of a desk or table and sharply snap down on the overhanging piece. The Lexan should break perfectly straight along the score.

7. Sand the edges with 100-grit paper to take off the sharp edges.

Tips & Warnings

• Wear eye protection when cutting Lexan with a band saw Do not try the scoring method of cutting Lexan over 1/2-inch thick. When cutting especially thick Lexan (over 1 inch thick) run a bead of machine oil along your cut-line before you begin cutting with the band saw. This will help to keep your saw blade from overheating.