How to Cut Plexiglass for DIY Projects

• Leave the protective film on the plexiglass to prevent scratches.
• Measure twice to be sure of your cut and mark your cut line with a marker or grease pencil on the protective-film-side of the plexiglass.
• Place a straightedge along the marked line to guide straight cuts.

• Put the plexiglass on a flat work surface.
• Clamp the sheet firmly so it won’t move while you cut. Support both sides of the plexiglass to prevent cracking.
• Choose the next steps below depending on the cutting tool you’re using.

• If the plexiglass is less than 1/8 of an inch thick, you may be able to use a utility knife.
• Align a straightedge on the marked line.
• Score the film and acrylic deeply with the utility knife, using multiple passes.
• Flip the sheet over and score the opposite side along the same line.
• Snap the sheet cleanly along the line by applying slow, even pressure.

• This method is best for long, straight cuts on thicker plexiglass sheets.
• Fit a fine-tooth blade rated for plastic or laminate to your saw.
• Set the blade height slightly higher than material thickness if using a table saw.
• Cut at a steady speed; don’t force the cut.
• Use a sacrificial board under the plexiglass to minimize chipping.

• Using a jigsaw is the best method for detailed cuts.
• Install a fine-tooth blade suitable for plastic or metal.
• Clamp and fully support the sheet to prevent vibration.
• Cut slowly, following the line. Let the blade do the work to avoid melting.

• Using a rotary tool is best for small cuts, notches or trimming.
• Attach a plastic-cutting wheel.
• Make light passes, removing small amounts at a time.
• Avoid prolonged contact that can melt the edge of the plexiglass.

• Remove the protective film.
• Smooth cut edges with fine-grit sandpaper or a fine sanding block.
• For a polished look, sand progressively from coarse to fine grit then buff.

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Overview:

• Plexiglass is lightweight, durable and easy to cut when using the right tools and techniques.
• Common projects include picture frames, window inserts and crafts.
• Always follow tool manufacturer safety guidelines and wear proper protective gear.

General Preparation:

• Leave the protective film on the plexiglass during cutting to avoid scratches.
• Measure carefully and mark cut lines on the film side.
• Secure the sheet on a flat surface and support offcuts to prevent cracking.

Cutting Methods:

• Thin sheets (under 1/8 of an inch) can be scored with a utility knife and snapped cleanly.
• Circular saws or table saws work best for long, straight cuts on thicker sheets.
• Jigsaws are ideal for curves and detailed shapes when used slowly.
• Rotary tools are best for small detail cuts, trimming and notches.

A circular saw or table saw with a fine-tooth blade made for plastic gives the cleanest straight cuts. For thin sheets, a utility knife can also produce clean results.

Yes. Secure the sheet fully, cut slowly and support both sides of the cut. Avoid forcing the tool and keep vibration to a minimum.

There’s no difference. Plexiglass is a brand name for a type of acrylic, so the cutting methods and tools are the same.

Yes. A jigsaw works well for curves when used with a fine-tooth blade. A rotary tool is best for small cuts, trimming or detail work.

Use sharp, fine-tooth blades and cut at a slow, steady speed. Pausing between passes and avoiding excess pressure also helps reduce heat buildup.