how to cut plexiglass

3 hours ago 3

To cut plexiglass effectively, the method depends on the thickness and the type of cut you need:

Scoring and snapping by hand:
Use a utility knife, box cutter, or a specialty plastic-cutting knife.
1. Place a ruler or straightedge along the marked cutting line.
2. Score the plexiglass by repeatedly cutting along the line with firm pressure until a deep groove forms (this may take 6 to 12 passes).
3. Flip the sheet and score the opposite side along the same line.
4. Position the scored line over the edge of a sturdy work surface and apply sharp downward pressure to snap the plexiglass cleanly along the score.
  This method works well for straight cuts on thin sheets

Using a Dremel tool:
For complex shapes or curves on thin plexiglass, clamp the sheet securely and use a Dremel with an appropriate cutting bit at moderate speed (6-8). Keep the bit wet to avoid overheating and make multiple passes if needed

Power tools such as jigsaws, circular saws, or table saws:
Use a fine-tooth blade designed for plastic or a carbide-tipped metal cutting blade.
1. Clamp the plexiglass firmly to prevent movement.
2. Cut slowly at medium speed to avoid melting or cracking.
3. Pause occasionally to cool the blade, or spray water on the cutting area to prevent overheating.
4. For jigsaws, use a blade with about 10 teeth per inch (TPI) and a low speed setting to reduce vibration and cracking. Masking tape along the cut line can help dampen vibrations

After cutting, edges may be rough. Smooth them by wet sanding starting with 120-grit sandpaper and progressing to 600-grit.
For a polished finish, use a buffer attachment on a power drill to buff the edges

Always wear safety goggles and gloves.
If using power tools, also use ear protection and a dust mask.
Leave the protective masking film on the plexiglass during cutting to reduce scratches

This approach ensures clean, precise cuts whether working with thin or thick plexiglass sheets.