Tools and Materials
Materials
Circular saw with fine-tooth blade
Grease pencil or marker
Straightedge or ruler
- Clamps
Steps to Cut a Plexiglass
Cutting plexiglass doesn’t have to be complicated. Just follow these easy steps to get the job done right.
Before you begin the process of cutting plexiglass, it's important to prepare your workspace to ensure safety and accuracy.
- Take a Plexiglass Sheet: Start by choosing the right size and thickness of plexiglass for your project. Keep the protective paper or a plastic film on until the cutting is complete to prevent scratches during handling.
- Set Up Your Work Area: Lay the plexiglass flat on a stable surface, such as a workbench or a table, making sure that the entire sheet is supported, especially if you're working with a large piece.
- Secure the Plexiglass: Use clamps to hold the plexiglass in place. This prevents it from moving during the cutting process.
Always wear safety goggles and gloves when cutting plexiglass, as it can produce sharp splinters.
Accurate marking is important for getting a clean and straight cut.
- Measure Precisely: With the help of a measuring tape, determine the dimensions of the piece you want to cut from the plexiglass sheet.
- Mark the Dimensions: Use a grease pencil or marker to apply your measurements onto the plexiglass.
- Use a ruler: Connect your marks with a ruler, creating a clear and precise guideline for cutting.
Can You Use a Box Cutter to Cut Plexiglass
- Score the Line: Place a ruler along the line where you want to cut. Use the box cutter to make several cuts along the line, pressing firmly. The aim is to create a deep cut.
- Flip and Repeat: Flip the plexiglass over and score the same line on the other side.
- Snap the Plexiglass: Position the scored line over the edge of a table or workbench, with the line hanging off. Press down firmly on the sheet to snap it along the scored line.
Make multiple small marks along your measurement line and connect them with the ruler to ensure precision.
Using a box cutter is effective for smaller, thin sheets of plexiglass but not recommended for thicker sheets, which require a saw for a cleaner, safer cut.
This simple method will help you learn how to cut plexiglass with a circular saw cleanly and safely.
- Attach the Right Blade: Fix a fine-tooth blade made for cutting plastic onto your circular saw.
- Set Up the Plexiglass: Place the plexiglass on your workbench or table and make sure the line you marked earlier lines up with where your saw blade will go.
- Secure the Sheet: Clamp the plexiglass firmly to make sure it doesn't move while you're cutting.
- Start Cutting Carefully: Turn on the circular saw and move it slowly along the marked line on the plexiglass. Keep the saw speed on medium to avoid heating up the plexiglass too much, which can make it melt. If the plexiglass starts getting too hot, you can lightly spray water on the area you're cutting to cool it down.
- Check Your Work: After finishing your cut, unclamp the plexiglass and take a look at the edges to make sure they are even.
How to Achieve a Clean Cut in Plexiglass
Getting a smooth, clean cut on plexiglass helps your project look professional. Here are some tips that you can consider to achieve it:
- Use a Fine-Tooth Blade: Choose a blade made for cutting plastic, ideally one with 80 teeth or more. This reduces chipping and cracking.
- Go Slowly with Medium Speed: Avoid high speed, which can overheat and melt the plexiglass. Use steady, gentle pressure as you cut.
- Secure the Plexiglass: Clamp it tightly to prevent any movement, which helps keep your cut straight and accurate.
- Cool the Cutting Area: Plexiglass can melt from the friction, so spray water on the cutting line if it heats up.
- Score and Snap for Thin Sheets: For thin plexiglass (under 3mm), score the line with a utility knife, then snap it along the cut line instead of using a saw.
When Is Plexiglass Not the Best Choice?
Plexiglass is a great option for many projects, but it may not be the best choice for areas that need strong impact resistance or are exposed to heavy use. It’s also not ideal for high-heat environments or places where heavy weight is required.
Plexiglass can scratch, crack, or yellow over time if left in direct sunlight. For these situations, materials like polycarbonate, tempered glass, or metal may provide better durability and performance.
- After cutting plexiglass, the edges may be rough or uneven.
- Start with wet sanding the edges of the plexiglass by using 120-grit sandpaper that has been slightly moistened with water. This process helps to keep dust at bay and prevents the plexiglass from getting too hot.
- Gradually move to finer sandpaper up to 600 grit to achieve a smoother finish.
- For an extra polished edge, use a buffer attachment on a drill to buff the edges to give it a clear, glossy finish.
Be cautious while sanding to avoid over-smoothing, which could alter the piece’s dimensions.