Black Perspex Cut To Size? The 103 Latest Answer

There are many options for clear plastic sheet today and most people don’t know the difference between the two main options: Perspex® cast acrylic sheet and polycarbonate sheet. Each blade is made differently and with different materials, hence the difference in features and price. Plexiglas has a variety of benefits listed below.

Acrylic sheet, also known as polymethyl methacrylate (PMMA) sheet, is made from a derivative of natural gas and is traded under the name Perspex® along with other brand names. Polycarbonate is sold under the trade names Lexan® and Makrolon® and is used in a variety of applications. Polycarbonate is more expensive, with its main advantages being extremely high impact resistance and good fire resistance, hence its association with bulletproofing, as it is the material used for armored car windows, anti-vandalism and the manufacture of electronic instrument cases.

At first glance, these two clear materials may seem similar, but it’s important to understand their difference so you can choose the best one for the project you’re working on. Due to its specific characteristics, one may favor your needs while the other may not fully meet your purposes. Here are some qualitative differences between these two common materials:

Thickness of the Plexiglas plate

Both materials weigh half the weight of regular glass, but are far stronger than glass. Perspex® acrylic sheet withstands 17 times more impact than glass, while polycarbonate can withstand 250 times more impact than glass. Polycarbonate is more flexible than acrylic, but will flex more under stress. Acrylic is stiffer and can break under extreme impact.

light and clarity

Continued exposure to sunlight on standard polycarbonate will yellow it, although sheets can be treated to give a UV resistant product to minimize yellowing. UV stable polycarbonate sheet has a typical outdoor product warranty of up to 10 years, while Perspex® clear cast acrylic sheet has a 30 year outdoor warranty.

Polycarbonate sheets have a light transmission of 89% compared to 92% for acrylic. Acrylic sheets have the advantage of being easier to polish to restore clarity, while polycarbonate is more difficult to do so.

working temperature range

Perspex® cast acrylic sheet has a wide temperature range in which it can be used with a working temperature range of -40 to 190 degrees F. They can expand and contract with changes in temperature, but will not shrink permanently over time. Polycarbonate, on the other hand, can withstand temperatures of up to 240 degrees Fahrenheit.

Cut

Both materials can be cut with conventional tools such as routers and saws. Perspex® acrylic sheet is easier to cut than polycarbonate, which is known for withstanding the initial impact of the saw at the start of the cut. If you cut polycarbonate sheets with a laser they will turn yellow and is therefore not fully recommended. On the other hand, a clear Perspex® acrylic sheet gives a high gloss edge directly when laser cut.

Drilling plexiglass panels

If you drill Perspex® acrylic near the edge or with a drill not recommended for plastics, there is a risk of cracking. Polycarbonate, on the other hand, will not crack when drilled with a standard drill bit, even close to the edge.

editing

Polycarbonate offers flexible use in machining where its impact resistance makes it less prone to breakage during machining than acrylic. Intricate machining of cast Perspex® acrylic sheet is also common, with many users creating complex designs.

polishing

If you want to buff the edges of acrylic for a smooth look, then you’re in luck – flame or buff buffing acrylic sheets easily gives a glossy polished edge. Polycarbonate is not as easy to polish and does not give such a clear edge.

heat bending

When working with cast Perspex® acrylic sheet, heat bending works well to achieve very tight product radii. Polycarbonate sheets can also be cold bent/cold formed without heating, but only to a smaller radius.

Adhere

Acrylic gives a final cleaner bond than polycarbonate when cemented with the recommended adhesive.

Clean Plexiglas film

Both materials are easily cleaned with a 100% cotton cloth or microfiber and plain soapy water. It is not recommended to clean these materials with an organic solvent as it may cause damage.

durability

Polycarbonate sheets scratch more easily than Perspex® cast acrylic sheets. In addition, cast Perspex® acrylic sheet has much better chemical resistance than polycarbonate to a wide range of acids, bases, alcohols and hydrocarbon products (e.g. gasoline).

Both products can be guaranteed for outdoor use although care must be taken to ensure the correct polycarbonate product is used.

Color selection of the plexiglass plate

Polycarbonate sheets have a limited range of colors while plexiglass sheets come in a variety of colors.

Therefore, these two materials have different uses depending on their properties listed above.

Perspex® cast acrylic sheet is used in areas where optimum weather and abuse resistance is required because it withstands weather, sunlight and general handling better than polycarbonate. It finds applications in areas such as corporate signage, ice hockey spectator protection, helicopter windows, motorcycle wind deflectors, caravan glazing and automotive taillights. Other special applications are large aquariums and pool windows.

Polycarbonate, on the other hand, is highly resistant to impact forces and does not break easily, hence its use in anti-riot shields and visors, bulletproof glass if the layers are thick enough, DVDs, sunglasses, goggles, vehicle headlights, ATV glazing, and water bottles .

For more information, call 1300.465.888 or contact us today.

In a range of applications from picture frames to table tops, plexiglass (also known as acrylic) serves as a cost-effective, shatterproof replacement for glass. In fact, many do-it-yourselfers prefer plexiglass for its light weight and durability, not least because it can be cut and shaped with common workshop tools.

As versatile and tough as it is, Plexiglas isn’t perfect. For one, it scratches easily. That is why the webs of the material are covered with a thin protective film. The other downside? Homeowners who don’t know how to cut plexiglass may be intimidated by the material at first – but we’re here to help!

When cutting plexiglass, leave the film in place for as long as possible to avoid damaging the surface. Second, remember that even if you are careful, plexiglass can be difficult to cut without leaving a rough, jagged edge. If your project calls for a clean edge, expect to spend energy smoothing the finish. Simply cutting plexiglass is comparatively easy.

Read on to learn how to properly cut plexiglass.

How to cut a thin sheet of plexiglass (using a utility knife, box cutter, or glass cutter)

For a thin sheet of plexiglass – i.e. H. Material up to 3/16 inch thick – a scoring method not dissimilar to a technique used to cut real glass.

Lay the sheet on a flat surface and use a folding ruler and a permanent marker (or a bold marker) to measure and draw the line you want to cut.

Next, hold the ruler against the marked line and run the blunt side of a utility knife or a special Plexiglas cutting tool along the ruler to score the panel. Score repeatedly, up to 10 or 12 times, until you have made a deep groove in the Plexiglas. Turn the plexiglass over and cut the opposite side in the same way. Finally, hold the scribed line against the edge of your work surface and secure the plexiglass with a clamp. Then, using strong downward pressure, break off the part of the plexiglass that protrudes above the work surface.

RELATED ARTICLE: How to Clean Plexiglas

advertisement

How to Cut a Thick Sheet of Plexiglas (Using a Circular Saw, Reciprocating Saw, Table Saw, or Jigsaw)

For thicker Plexiglas sheets, cut with a chainsaw – be it a circular saw, saber saw or table saw. (To cut something other than a straight line, opt for a jigsaw.)

No matter what type of saw you choose for the job, using the right saw blade is crucial. There are special blades made specifically for acrylic, but any metal cutting blade with carbide tips will do the trick. Before deciding on one blade or another, check that the teeth are evenly spaced, have no rake, and are of a uniform height and shape.

After preparing your tool, measure and mark the plexiglass, then cut like any other material and clamp if necessary. A note of caution: If the blade overheats, the material may chip or crack. Proceed accordingly by cooling the blade with water or stopping your work for a few minutes as needed.

How to buff and buff cut edges

Whichever cutting method you choose, you will find that the cut Plexiglas edge does not look particularly attractive. If the raw edge would be visible in your application, take the extra time to sand and buff the imperfections. Note: You can use a hand sander, but manual wet sanding usually produces the best results.

Start the process with 120 or 180 grit waterproof sandpaper in combination with a wooden or rubber sanding block. As the plexiglass becomes smoother, move to progressively finer grits. Finally, sand with 600 grit sandpaper. When you are satisfied with the edge’s appearance, proceed to buffing. Equip your drill with a polishing pad and, after applying a polishing paste formulated for plastic, bring the Plexiglas edge to a perfect shine.

Tips to avoid plexiglass when cutting

Although plexiglass is a durable material, it is not unbreakable. Consider the following tips when learning how to cut plexiglass to avoid irreversible damage.

advertisement

Leave the plastic wrap on. As mentioned above, plexiglass usually comes with a thin layer of plastic film to prevent scratches as the material is transported from the manufacturer to the retailer to your workshop. Keeping this film on while measuring, marking and cutting will avoid scratching your tools and work surfaces.

As mentioned above, plexiglass usually comes with a thin layer of plastic film to prevent scratches as the material is transported from the manufacturer to the retailer to your workshop. Keeping this film on while measuring, marking and cutting will avoid scratching your tools and work surfaces. points deep. When cutting plexiglass with a knife like a box cutter, be sure to cut a straight, deep line before attempting to break the material at the mark.

When cutting plexiglass with a knife like a box cutter, be sure to cut a straight, deep line before attempting to break the material at the mark. Use the right blade. Whether you’re cutting plexiglass with a hand tool or a chainsaw, it’s important to use a sharp blade. A dull blade will struggle with the material and potentially cause cracks and breakage – not to mention an overly rough cutting edge.

Whether you’re cutting plexiglass with a hand tool or a chainsaw, it’s important to use a sharp blade. A dull blade will struggle with the material and potentially cause cracks and breakage – not to mention an overly rough cutting edge. Keep the blade cool. As previously mentioned, an overheated blade on a chainsaw can also cause plexiglass to crack and break during the cutting process. Leaving the thin film of plastic on the surface acts as a lubricant to some extent, but if your blade starts to overheat, stop the saw and turn it off to let it cool. You can also put a small amount of soapy water on the plexiglass surface for extra lubrication as you cut.

RELATED: How to cut plastic

Final Thoughts on Cutting Plexiglas

Each building material has a number of quirks and nuances that you can master with practice. Thankfully, DIYers with woodworking experience don’t take long to learn how to cut plexiglass.

While you may only need to cut a piece of acrylic to begin with, learning to work with this versatile, transparent material will open up a new universe of DIY possibilities for you to explore in countless projects for years to come.

Written by MS

Here at The Plastic People we know quite a bit about different plastic materials and their uses and properties. Of all the plastics we work with on a daily basis, acrylic (aka plexiglass, perspex and PMMA) is one of our favorite materials because it’s just so easy to work with.

Because of this, we think acrylic is the perfect DIY material for a range of home projects. It’s lightweight, affordable, and shatterproof. In this blog, we discuss the five main methods you can use to cut acrylic sheets/sheets into any size or shape you want for your DIY projects. Towards the end we also explain the best ways to ensure you get a good finish on your plastic.

If DIY isn’t your thing, or you’re looking for a more complex and intricate acrylic cut shape/design, then contact our team today! We cut acrylic – and a range of other plastics including PVC and polycarbonate – into any size and shape.

hand saw

Using a handsaw to cut your acrylic material is perhaps the most universal option – and it’s a pretty low skill. However, this method requires more concentration and effort than using an electric saw, such as a power saw. B. a jigsaw or band saw.

Tool:

Here at The Plastic People we know quite a bit about different plastic materials and their uses and properties. Of all the plastics we work with on a daily basis, acrylic (aka plexiglass, perspex and PMMA) is one of our favorite materials because it’s just so easy to work with. That’s why we think acrylic is the perfect DIY material for a range of home improvement projects. It’s lightweight, affordable, and shatterproof. In this blog, we discuss the five main methods you can use to cut acrylic sheets/sheets into any size or shape you want for your DIY projects. Towards the end we also explain the best way to ensure your plastic gets a good finish. If DIY isn’t your thing or you’re looking for a more complex and intricate shape/acrylic cut design, then hop on and contact our team today! We cut acrylic – and a range of other plastics including PVC and polycarbonate – into any size and shape. Check out our services by clicking here and get an instant quote today. Using a handsaw to cut your acrylic material is perhaps the most universal option – and it’s a pretty low skill. However, this method requires more concentration and effort than using an electric saw, such as a power saw. B. a jigsaw or band saw.

Fine-toothed handsaw (helps you avoid jagged edges)

ruler and marker pen

Solid, flat cut surface

clamp (optional)

The process:

Start by making a guide for yourself directly on the plastic surface using a marker pen. Straight lines are the easiest to cleanly cut. Clamp your acrylic (or weight it down on one end to stabilize the material). Finally, start cutting. Make sure not to use a wood saw as this can damage the material – we recommend a fine-toothed hacksaw or similar tool. Try to keep the acrylic as still as possible to avoid warping your cut path.

result and break

Scoring and breaking your acrylic sheet is a relatively quick and hassle-free way to cut plastic to size. Note: This method should only be used on acrylic under 5mm.

Tool:

Ruler/ruler and marker

scoring knife

Solid, flat cut surface

clamp (optional)

The process:

As above, you want to start by marking the area you want to cut and then attach the acrylic sheet to your cutting surface. Next, using your ruler as a guide, run the scoring knife across the surface of the plastic a few times to create a narrow score. Lay the edge you want to remove over the edge of your flat surface and, in one quick motion, press down on the overhanging edge (or plastic scrap). The plastic will start to end and then break, leaving you with two sheets of acrylic.

puzzle

Using a jigsaw has the advantage of efficiency over our previous two options. It is quicker to process and therefore requires less concentration. You can also create more complicated cuts with an electric saw as it is easier to manipulate your tool.

Tool:

Jigsaw with a fine-toothed blade

Ruler/ruler and marker

safety goggles

level work surface

clamp (optional)

The process:

Again, start creating a guide line on the surface of the acrylic. You can cut a straight edge with a jigsaw, or opt for a more freehand curve if you want to create a circular piece of plastic. Clamp the area and put on your safety goggles in case plastic particles come loose during the cutting process. Tensioning is very important when using a jigsaw as it keeps the plastic from vibrating and moving. Saw through the plastic. When using electric saws it is best to work quickly as they generate additional heat which could bend/warp the acrylic plastic.

band saw

Band saws tend to be fairly large machines that you only find on workshops and factory floors. For example, we use a form of band saw to prep and cut all of our acrylic sheets here at The Plastic People’s factory!

Tool:

band saw

Highlighter

safety goggles

The process:

Start by marking your plastic. Some high tech band saws come with guides built into the machine, so you may be able to avoid this step. With your safety goggles on, turn on the band saw and start feeding the plastic through the blade. There are different blade widths for band saws – depending on the plastic thickness and the desired shape. Do your research or read the manufacturer’s instructions before beginning.

As a rule of thumb, plexiglass is about 30 times more impact resistant than glass, but how does that work in practice? To properly answer this question, we must first look at the types of stress that a material can withstand. In mechanical engineering we know three types of loads: static, dynamic and sudden loads. If you look purely at the load that glazing (regardless of whether it is made of glass, polycarbonate or acrylic) can suffer, then dynamic and sudden loads are particularly important. Dynamic loading is caused by wind force and pressure differences on both sides of the glazing. Just look at a window of a closed room when suddenly a door is opened: you will see the window move. And although the movement is small, this is a heavy burden on glass.

Load capacity vs. impact

Looking at the resilience of acrylic, we can see that the weight needed to break an acrylic sheet is about 30 times that of a glass sheet of the same thickness. Suppose a 1 meter wide and 3 millimeter thick pane of glass breaks under a weight of 1 kilo, then a 3 millimeter thick acrylic pane breaks under a weight of 30 kilos. That’s quite a difference. This is also the reason why acrylic is widely used in load-bearing and heavily loaded structures such as display cases and aquariums.

The decisive factor is the resistance to jumping loads. This is when the glazing takes a sudden hit or hit. We know that glass breaks quickly. However, acrylic is flexible and will deform (bend) due to the force. The energy of the impact is converted into deformation – something glass can do only to a very limited extent. When acrylic is bent to its maximum it will break, but it takes a lot of energy to reach that maximum bending ratio. A rock thrown at Acryl will bounce off with the same force, the same goes for a hit. When the maximum bending ratio is reached, the force to break the surface is still 30 times higher than glass.

would fit my drill or get a special drill for it.”

…”

“It was important to learn that I need special drills and that I need to make sure they are

user friendliness

The first distinction between polycarbonate and acrylic can be made in terms of machinability, more specifically, cutting and drilling. Cutting acrylic sheets is much easier than cutting polycarbonate, which is much more resistant, even if you use special cutting machines.

However, when drilling, polycarbonate is much easier to work with. If you need a product that you can easily drill into and where leaks are easy to fix, you’re better off with polycarbonate, as acrylic can break or crack more easily.

transparency

When it comes to transparency, acrylic is a better option, especially for roofing applications. Both acrylic and polycarbonate are clear, but polycarbonate can begin to yellow when exposed to the sun.

With age, both acrylic and polycarbonate can begin to lose their transparency, but the transparency of acrylic can be restored by applying polish. However, once polycarbonate loses its transparency, it is permanent.

durability

Both acrylic and polycarbonate can withstand severe knocks and bumps without showing any signs of damage or deterioration. Heavy hitting on any of these plastics rarely causes damage as they are incredibly resistant to a wide range of materials – even metal.

When measured against each other, it becomes clear that polycarbonate is much stronger than acrylic. This means that if you prioritize strength over transparency, polycarbonate may be a better option for your roofing needs.

Colours

Acrylic is available in a variety of colors. Polycarbonate, on the other hand, is only available in a few colors. Also keep in mind that polycarbonate has a tendency to yellow when exposed to sunlight, making acrylic the best color choice for roofing.

Easy cleaning

Both acrylic and polycarbonate are easy to clean with non-abrasive materials such as soap and water. Although both of these materials are used in bulletproof gear, they can resist scratches, so it’s important to avoid using abrasive cleaning products like harsh sponges.

It is also important to avoid using strong chemicals to clean these plastics. While polycarbonate is more chemical resistant than acrylic, substances like ammonia can cause damage over time.

Although both acrylic and polycarbonate can scratch and yellow from exposure to the sun, it is important to remember that only acrylic can be treated for this type of damage.

Costs

Typically, polycarbonate can be significantly more expensive than acrylic, which is significant for large roofing projects.

What is the difference between polycarbonate and acrylic?

Advantages and disadvantages of acrylic and polycarbonate

Acrylic or plexiglass sheets Advantages of polycarbonate sheets Easier to work with than polycarbonate

Can be polished, both for scratches and clean edges

Better bonding

shinier

Up to 35% cheaper than polycarbonate. Stronger than acrylic

More flexible than acrylic; can be molded at room temperature

Can be exposed to high temperatures and is non-flammable

Very resistant to chemicals

Can be drilled without cracking

Lighter weight than comparable acrylic. Disadvantages stiffer

It is more likely to tear on drilling or on impact

More likely to chip

Should not be exposed to open fire, scratches easily

Cannot be polished

Can be dented easily

More translucent than transparent compared to acrylic

How to choose between polycarbonate and acrylic

The best choice between clear or near-clear plastics, acrylic plexiglass sheets and polycarbonate sheets is often seen as the solution to a wide range of optical applications. How do they compare? Both acrylic and polycarbonate weigh half as much as comparable sized glass by volume. For what you lose in weight, you gain strength with both products. Both are made of synthetic glass and offer enormous flexibility. Acrylic has about 17 times the impact strength. Polycarbonate is the stronger material with 250 times the impact strength of standard glass. Polycarbonate offers much more resilience than acrylic, making it ideal for very demanding applications such as bulletproof windows. Acrylic has a high gloss finish and is more transparent, making it ideal for display cases. Acrylic is also easier to crack while polycarbonate is easier to scratch. Acrylic is also less expensive than polycarbonate and unlike polycarbonate, acrylic can be heated and shaped and then reheated while retaining its high quality appearance. To find the right material for your project, it’s important to take the time to compare the two plastics side-by-side. This can give you a better idea of ​​which will work best for your specific project. However, depending on what you are using acrylic or polycarbonate for, choosing the right plastic should be an easy decision.

To help you choose the right material for your sheet, rod or tube, here are some ideal uses for each plastic:

Acrylic Plastic Applications

Window and glass replacement

insulations

craft projects

retail displays

Polycarbonate Plastic Applications

Bullet-proof windows

Clear molds for pouring

Models for high temperature applications

Additional polycarbonate and acrylic resources

Plexiglas is a form of acrylic plastic that is initially liquid and then formed into a strong plastic. Acrylic is one of the best substitutes for glass due to its durability, flexibility and sustainability. Over the years the use of high quality acrylic has expanded to multiple applications. Originally used to make windows for submarines and cars, acrylic sheet now has a variety of alternative uses (including construction, engineering, and even photography). A durable plastic, it’s versatile, inexpensive, and a practical alternative to glass.

Below are some of the pros and cons of using acrylic sheets.

Advantages of acrylic sheets

UV-resistant:

Being flexible and easy to mold into any shape, acrylic is perfect for making various products. They are an ideal product for outdoor use as they are heat resistant up to 160 degrees C.

reusable

Many restaurants prefer acrylic tableware and glassware because it is durable, shatterproof and easy to clean.

Environmentally friendly

Because it is synthetic, acrylic (e.g. plexiglass) is easy to reuse. Because of the many ways acrylic sheets can be made into other things (plates, acrylic table tops, secondary glazing or shelving), this is an eco-friendly choice.

Offers a wide range of colors

Acrylic sheets are available in a wide range of colors and designs. Depending on what you are using the material for, you can choose colored sheets or opt for clear acrylic sheets. These sheets come in a variety of styles including frosted acrylic, fluorescent acrylic, and mirror acrylic.

Dishwasher safe

Tableware and glassware made from Perspex sheet has been designed to withstand the heat of a commercial dishwasher.

cost efficient

Synthetically manufactured glass-look acrylic is cheaper to produce and buy, making it a great alternative to glass.

Disadvantages of acrylic panels

Low quality

Plexiglas sheets melt at high temperatures or when exposed to direct flames. The melting point of acrylic plastic is 160 degrees C, so they cannot withstand extreme temperatures. Acrylic is strong and durable, but also scratched easily.

toxicity

Highly toxic fumes can be released during the manufacturing process of acrylic products. Those who produce acrylic glass receive protective equipment and clothing. There is also a risk of the acrylic exploding during polymerization if you don’t take proper precautions.

difficulties in recycling

Acrylic is recyclable, but since it’s not biodegradable, the process isn’t as simple as throwing it in your recycling bin or taking it to a glass recycling bin. But you can reuse acrylic (e.g. Plexiglas) by cutting larger sheets into small pieces and shaping them into other products.

When you think of windows, you most likely think of thick panes of traditional glass panels. For years, traditional glass was the only material used in windows, but as polycarbonate sheet and acrylic sheet have gained prominence, they are both now popular alternatives for glazing applications. So why should you choose acrylic sheets instead of traditional glass for your windows? There are a few reasons, but we’ll talk about the four main ones.

savings measures

If you’re a cost-conscious business owner or consumer, you’ll be pleased to know that plexiglass sheets are an economically conservative alternative to using glass. Plastics such as acrylic plexiglass panels require less energy and money to manufacture, are lighter than glass, so their transport and shipping costs are lower. The actual cost savings of the product will depend on the type of acrylic sheet you purchase as there are regular clear acrylic sheets as well as colored acrylic sheets, mirrored acrylic sheets, plexiglass sheets and more. Additionally, plexiglass sheeting does not require the additional purchase of coatings and foils as you can buy plexiglass with these properties already in impact modified acrylic sheet, UV filtering plexiglass, UV transmissive plexiglass and more.

security and strength

There are a number of reasons you might want higher strength windows, whether you have large dogs, live in a hurricane-prone region, or are concerned about strangers breaking in. Acrylic has much more strength to shatter than glass. By using acrylic sheets as window panes, you no longer have to worry about someone getting hurt if a pane breaks. Plexiglas sheets are unique in that while extremely difficult to break, they can shatter, but will not shatter into a thousand tiny, dangerous shards.

creativity and ease of use

Although these are two separate benefits, the ease of use of acrylic sheets is directly related to their ability to be used creatively. Acrylic sheets are much easier to cut than glass. Acrylic sheets can be cut similar to wood with similar tools such as a router, scoring tool, or table saw. Additionally, a Plexiglas panel weighs about half that of glass, making it much easier to move, cut, and install. Because it can be easily cut and is relatively lightweight compared to traditional glass, acrylic sheet is ideal for use in the manufacture of accent or design windows. Glass is not practical when designing windows for architectural pieces and is too brittle and stiff. The flexible polymers in Plexiglas allow for custom shapes and designs. In addition, acrylic sheets come in a variety of styles, including colored acrylic sheets, fluorescent acrylic sheets, and black and white acrylic sheets.

light transmission

One of the best reasons to buy acrylic plastic sheets over traditional glass is to remove glare and reflections. The clarity of the plexiglass sheet allows more than 90% of light to pass through, making it more transparent than glass. Glass reflects more light and the thicker the glass, the more discoloration you will notice. Regardless of the thickness of the Plexiglas, however, it always remains clear.

When you look at all the advantages that acrylic glass has over traditional glass for window applications, it is logical that manufacturers have chosen plexiglass for years. That’s not to say that traditional glass doesn’t have its advantages, but Plexiglas is a more durable, versatile, and economically viable alternative to glass.

In a range of applications from picture frames to table tops, plexiglass (also known as acrylic) serves as a cost-effective, shatterproof replacement for glass. In fact, many do-it-yourselfers prefer plexiglass for its light weight and durability, not least because it can be cut and shaped with common workshop tools.

As versatile and tough as it is, Plexiglas isn’t perfect. For one, it scratches easily. That is why the webs of the material are covered with a thin protective film. The other downside? Homeowners who don’t know how to cut plexiglass may be intimidated by the material at first – but we’re here to help!

When cutting plexiglass, leave the film in place for as long as possible to avoid damaging the surface. Second, remember that even if you are careful, plexiglass can be difficult to cut without leaving a rough, jagged edge. If your project calls for a clean edge, expect to spend energy smoothing the finish. Simply cutting plexiglass is comparatively easy.

Read on to learn how to properly cut plexiglass.

How to cut a thin sheet of plexiglass (using a utility knife, box cutter, or glass cutter)

For a thin sheet of plexiglass – i.e. H. Material up to 3/16 inch thick – a scoring method not dissimilar to a technique used to cut real glass.

Lay the sheet on a flat surface and use a folding ruler and a permanent marker (or a bold marker) to measure and draw the line you want to cut.

Next, hold the ruler against the marked line and run the blunt side of a utility knife or a special Plexiglas cutting tool along the ruler to score the panel. Score repeatedly, up to 10 or 12 times, until you have made a deep groove in the Plexiglas. Turn the plexiglass over and cut the opposite side in the same way. Finally, hold the scribed line against the edge of your work surface and secure the plexiglass with a clamp. Then, using strong downward pressure, break off the part of the plexiglass that protrudes above the work surface.

RELATED ARTICLE: How to Clean Plexiglas

advertisement

How to Cut a Thick Sheet of Plexiglas (Using a Circular Saw, Reciprocating Saw, Table Saw, or Jigsaw)

For thicker Plexiglas sheets, cut with a chainsaw – be it a circular saw, saber saw or table saw. (To cut something other than a straight line, opt for a jigsaw.)

No matter what type of saw you choose for the job, using the right saw blade is crucial. There are special blades made specifically for acrylic, but any metal cutting blade with carbide tips will do the trick. Before deciding on one blade or another, check that the teeth are evenly spaced, have no rake, and are of a uniform height and shape.

After preparing your tool, measure and mark the plexiglass, then cut like any other material and clamp if necessary. A note of caution: If the blade overheats, the material may chip or crack. Proceed accordingly by cooling the blade with water or stopping your work for a few minutes as needed.

How to buff and buff cut edges

Whichever cutting method you choose, you will find that the cut Plexiglas edge does not look particularly attractive. If the raw edge would be visible in your application, take the extra time to sand and buff the imperfections. Note: You can use a hand sander, but manual wet sanding usually produces the best results.

Start the process with 120 or 180 grit waterproof sandpaper in combination with a wooden or rubber sanding block. As the plexiglass becomes smoother, move to progressively finer grits. Finally, sand with 600 grit sandpaper. When you are satisfied with the edge’s appearance, proceed to buffing. Equip your drill with a polishing pad and, after applying a polishing paste formulated for plastic, bring the Plexiglas edge to a perfect shine.

Tips to avoid plexiglass when cutting

Although plexiglass is a durable material, it is not unbreakable. Consider the following tips when learning how to cut plexiglass to avoid irreversible damage.

advertisement

Leave the plastic wrap on. As mentioned above, plexiglass usually comes with a thin layer of plastic film to prevent scratches as the material is transported from the manufacturer to the retailer to your workshop. Keeping this film on while measuring, marking and cutting will avoid scratching your tools and work surfaces.

As mentioned above, plexiglass usually comes with a thin layer of plastic film to prevent scratches as the material is transported from the manufacturer to the retailer to your workshop. Keeping this film on while measuring, marking and cutting will avoid scratching your tools and work surfaces. points deep. When cutting plexiglass with a knife like a box cutter, be sure to cut a straight, deep line before attempting to break the material at the mark.

When cutting plexiglass with a knife like a box cutter, be sure to cut a straight, deep line before attempting to break the material at the mark. Use the right blade. Whether you’re cutting plexiglass with a hand tool or a chainsaw, it’s important to use a sharp blade. A dull blade will struggle with the material and potentially cause cracks and breakage – not to mention an overly rough cutting edge.

Whether you’re cutting plexiglass with a hand tool or a chainsaw, it’s important to use a sharp blade. A dull blade will struggle with the material and potentially cause cracks and breakage – not to mention an overly rough cutting edge. Keep the blade cool. As previously mentioned, an overheated blade on a chainsaw can also cause plexiglass to crack and break during the cutting process. Leaving the thin film of plastic on the surface acts as a lubricant to some extent, but if your blade starts to overheat, stop the saw and turn it off to let it cool. You can also put a small amount of soapy water on the plexiglass surface for extra lubrication as you cut.

RELATED: How to cut plastic

Final Thoughts on Cutting Plexiglas

Each building material has a number of quirks and nuances that you can master with practice. Thankfully, DIYers with woodworking experience don’t take long to learn how to cut plexiglass.

While you may only need to cut a piece of acrylic to begin with, learning to work with this versatile, transparent material will open up a new universe of DIY possibilities for you to explore in countless projects for years to come.

Written by MS

Here at The Plastic People we know quite a bit about different plastic materials and their uses and properties. Of all the plastics we work with on a daily basis, acrylic (aka plexiglass, perspex and PMMA) is one of our favorite materials because it’s just so easy to work with.

Because of this, we think acrylic is the perfect DIY material for a range of home projects. It’s lightweight, affordable, and shatterproof. In this blog, we discuss the five main methods you can use to cut acrylic sheets/sheets into any size or shape you want for your DIY projects. Towards the end we also explain the best ways to ensure you get a good finish on your plastic.

If DIY isn’t your thing, or you’re looking for a more complex and intricate acrylic cut shape/design, then contact our team today! We cut acrylic – and a range of other plastics including PVC and polycarbonate – into any size and shape.

hand saw

Using a handsaw to cut your acrylic material is perhaps the most universal option – and it’s a pretty low skill. However, this method requires more concentration and effort than using an electric saw, such as a power saw. B. a jigsaw or band saw.

Tool:

Here at The Plastic People we know quite a bit about different plastic materials and their uses and properties. Of all the plastics we work with on a daily basis, acrylic (aka plexiglass, perspex and PMMA) is one of our favorite materials because it’s just so easy to work with. That’s why we think acrylic is the perfect DIY material for a range of home improvement projects. It’s lightweight, affordable, and shatterproof. In this blog, we discuss the five main methods you can use to cut acrylic sheets/sheets into any size or shape you want for your DIY projects. Towards the end we also explain the best way to ensure your plastic gets a good finish. If DIY isn’t your thing or you’re looking for a more complex and intricate shape/acrylic cut design, then hop on and contact our team today! We cut acrylic – and a range of other plastics including PVC and polycarbonate – into any size and shape. Check out our services by clicking here and get an instant quote today. Using a handsaw to cut your acrylic material is perhaps the most universal option – and it’s a pretty low skill. However, this method requires more concentration and effort than using an electric saw, such as a power saw. B. a jigsaw or band saw.

Fine-toothed handsaw (helps you avoid jagged edges)

ruler and marker pen

Solid, flat cut surface

clamp (optional)

The process:

Start by making a guide for yourself directly on the plastic surface using a marker pen. Straight lines are the easiest to cleanly cut. Clamp your acrylic (or weight it down on one end to stabilize the material). Finally, start cutting. Make sure not to use a wood saw as this can damage the material – we recommend a fine-toothed hacksaw or similar tool. Try to keep the acrylic as still as possible to avoid warping your cut path.

result and break

Scoring and breaking your acrylic sheet is a relatively quick and hassle-free way to cut plastic to size. Note: This method should only be used on acrylic under 5mm.

Tool:

Ruler/ruler and marker

scoring knife

Solid, flat cut surface

clamp (optional)

The process:

As above, you want to start by marking the area you want to cut and then attach the acrylic sheet to your cutting surface. Next, using your ruler as a guide, run the scoring knife across the surface of the plastic a few times to create a narrow score. Lay the edge you want to remove over the edge of your flat surface and, in one quick motion, press down on the overhanging edge (or plastic scrap). The plastic will start to end and then break, leaving you with two sheets of acrylic.

puzzle

Using a jigsaw has the advantage of efficiency over our previous two options. It is quicker to process and therefore requires less concentration. You can also create more complicated cuts with an electric saw as it is easier to manipulate your tool.

Tool:

Jigsaw with a fine-toothed blade

Ruler/ruler and marker

safety goggles

level work surface

clamp (optional)

The process:

Again, start creating a guide line on the surface of the acrylic. You can cut a straight edge with a jigsaw, or opt for a more freehand curve if you want to create a circular piece of plastic. Clamp the area and put on your safety goggles in case plastic particles come loose during the cutting process. Tensioning is very important when using a jigsaw as it keeps the plastic from vibrating and moving. Saw through the plastic. When using electric saws it is best to work quickly as they generate additional heat which could bend/warp the acrylic plastic.

band saw

Band saws tend to be fairly large machines that you only find on workshops and factory floors. For example, we use a form of band saw to prep and cut all of our acrylic sheets here at The Plastic People’s factory!

Tool:

band saw

Highlighter

safety goggles

The process:

Start by marking your plastic. Some high tech band saws come with guides built into the machine, so you may be able to avoid this step. With your safety goggles on, turn on the band saw and start feeding the plastic through the blade. There are different blade widths for band saws – depending on the plastic thickness and the desired shape. Do your research or read the manufacturer’s instructions before beginning.