While cutting plexiglass isn't very complicated, it's important to have a few basics to prevent from breaking your sheet or injuring yourself. If you have experience with cutting tools, you are probably able to cut your plexiglass yourself (if not, consult a professional).
In this article, we will advise you on how to prepare your acrylic before cutting, the circular saw (skilsaw) or the jigsaw.
The preparation
Before you begin, it's important to know that you need to keep the paper or protective film in place. The protection can be removed at the very end of your work, or even before the installation of your part. Scratches will then be avoided during handling and cutting.
You can use a pencil to draw a cutting line directly on the protective paper. We suggest you add sticky paper over your line. This will prevent splinters when cutting! To work the finish of your piece with sandpaper (slices), remember to cut your piece slightly larger so that the measurements are exact after sanding!
Last but not least: the security notions. It is mandatory to wear safety glasses to avoid eye injuries with plastic shards. You should also remove anything that could get caught in the saw blade, including jewelry and loose clothing.
The skilsaw
For a straight line cutting, the skilsaw is the perfect tool! I recommend a 100 tooth carbide blade for a 10 inch diameter (about 3 teeth per inch). It is important the saw runs at full speed when it comes in contact with the plexiglass. You have to guide the saw gently through the sheet without it getting stuck.The acrylic pieces must be supported: if the scrap hangs in a vacuum, it will create a jitter effect and the risk of cracking the plastic is very high. Once again, a clamp can help. Keep your hands behind the tool at all times.
The jigsaw
Although the finish is much less aesthetic, the jigsaw is very easy to use. It allows you to cut, make interior cuts and curves easily in plastic. The blade must have as many teeth as possible. We recommend a finishing or metal blade. For the interior cutout, drill a first hole in your part to allow the blade to slip through. Adjust the speed of the blade with your confidence level. Do not force the blade when cutting, you must pass it delicately through the material and slow down in curves. The piece should be held in place throughout the cut to prevent the sheet from skipping and breaking. A clamp can help. Keep your hands behind the tool at all times.
For professional results, do not hesitate to contact us! Whether for table saw cutting, laser cutting or CNC cutting, we are the experts!
In summary,
Blade knife (Exacto) | Circular saw | Jigsaw |
We do not recommend this method due to the very high risk of injury. | - 100 teeth carbide blade - About 3 teeth per inch - Straight line cutting | - Finishing blade - Metal blade - Cutting straight lines, curve and cut interior |