How to Cut Plexiglass Material

Plexiglass can be cut into various shapes and sizes.

You can cut plexiglass with a utility knife, a hand saw or a variety of table-mounted or hand-held power saws. The method you choose depends on the plexiglass thickness and the cut complexity. Use a hand saw for a straight cut on a small sheet less than 1/4 inch thick, or a power saw for curves or shapes on thicknesses greater than 1/4 inch, using blades specially designed for cutting plastics.

Things You'll Need

• Ruler
• Grease pencil
• Utility knife
• Gloves
• Safety glasses
• Dust mask
• Hand or power saw
• Clamp
• Fine-grained sandpaper

Instructions

Preparing to Cut

1. Lay the plexiglass sheet on a flat, even surface. Leave the protective coating on the plexiglass to prevent scratches during cutting.

2. Measure and mark the pieces to be cut using a ruler and grease pencil. With the ruler as a straightedge, use a utility knife to score the line you wish to cut. Repeat the score until there is a heavy groove on the plexiglass surface that is easy to follow.

3. Put on gloves and safety glasses before starting to cut. Consider wearing a dust mask so you don't inhale plexiglass particles.

Using a Utility Knife and Pressure

1. Lay the measured and scored plexiglass sheet on an uncluttered, flat work surface. Position the sheet so the scored edge hangs off the surface by 1/4 to 1/2 inch.

2. Lean firmly on the portion of the plexiglass remaining on the table. Have another person hold the sheet or put a heavy object on it to keep it in place.

3. Break off the scored section with the opposite hand, using a quick, downward motion. This technique works best with small plexiglass sheets less than 1/4 inch thick, as it's difficult to exert an equal downward pressure over a large, thicker area without cracking the plexiglass.

Using a Hand Saw

1. Position the measured and scored sheet on the work surface with the scored edge overhanging the surface by 1/4 to 1/2 inch. To keep the sheet from vibrating or moving while cutting, clamp it in place or have another person hold it.

2. Choose a straight saw for long cuts and a coping, scroll or hacksaw for shorter cuts. Ensure the blade has uniformly sized and shaped teeth. The U.S. Plastics Corp. advises using a straight saw with at least 10 teeth per inch and a hacksaw with at least 18 teeth per inch.

3. Position the saw to begin cutting at the farthest end of the scored line. Moving the saw toward you, saw in a smooth, consistent motion without applying too much pressure. Continue sawing until you reach the nearest end of the scored line and the piece releases.

Power Saw

1. Position the measured and scored sheet on the work surface. Ensure the saw you've chosen has a sharp blade with evenly spaced teeth of the same height, or a carbide-tipped blade designed for cutting plastics.

2. Turn the saw on and run it at top speed on the setting you've chosen, before attempting to cut. When using a table saw, feed the plexiglass against the blade, staying on the scored line. If you're using a hand-held power saw, push the blade against the plexiglass along the scored line.

3. Experiment with saw speed and pressure, watching for signs of cracking or melting. If the saw speed is too slow, the blade will get caught and the plexiglass will crack and chip. Operating the saw too fast can overheat the blade and melt the plexiglass.

Tips & Warnings

• Test your skills on a scrap piece of plexiglass before cutting the real thing.

• Sand the edges of the newly cut plexiglass with fine-grained sandpaper. Unfinished edges can be rough or jagged and can cut as easily and quickly as glass fragments.

References

• U.S. Plastic Corp.: Cutting Acrylite Acrylic Sheets with Power Saws
• Tap Plastics: Cyro Tech Brief: #2 Cutting with Circular Saws
• Online Tips: How to Cut Plexiglass
• U.S. Plastics Corp.: Cutting Acrylite Acrylic Sheets with Hand Saws

Resources

• Rideout Plastics: Cutting Plexiglass--How to Cut and Fabricate Plexiglass Sheet