Plexiglass is an inexpensive and durable material that you can use for an infinite number of projects such as frames, table tops or as an unbreakable substitute for glass. It is light, inexpensive and lasts a long time because it does not rot and does not break. You can easily cut it to your needs with the right tools, proper precautions and the correct measurements. The thinnest sheets can be scored and split with a utility knife or other engraving tool; the thicker ones, on the other hand, must be cut with a circular saw if you have to make straight cuts or with a jigsaw in the case of irregular cuts.
Steps
Method 1 of 3: Engrave and Split Thin Plexiglass Slabs
Step 1. Place the Plexiglas on a work surface
In the case of thin plexiglass sheets (under 5mm thick), engraving and then breaking them is the easiest way to make a cut. Place the sheet on a table or workbench so that you can work on a stable surface.
- Make sure the surface is clean and free of any objects that could hinder your work or potentially mark or damage the sheet.
- Use a uniform and stable structure that does not risk wobbling.
Step 2. Draw a line with a dry-erase marker where you want to cut
Use a ruler as a guide as you draw a straight line where you want to cut the paper. The line should be clearly visible but be careful not to smudge the marker.
Use a dry-erase marker so you can remove the mark after cutting the sheet
Advise:
if you make a mistake while drawing the line, erase it completely and start from scratch. Use a damp cloth or paper towel to remove the marker mark.
Step 3. Score with a utility knife along the line you marked on the plexiglass sheet
Make sure the sheet is flat and stable on your work surface. Apply firm pressure and use a ruler to guide the utility knife as you drag it along the line you just drew. Pass the utility knife over the line up to 10 or 12 times, until the mark is deep enough.
- You can also use another cutting tool if its blade is sharp enough to engrave the plexiglass.
- The deeper you make the cuts, the easier it will be to break the plexiglass.
Step 4. Turn the paper over and engrave the other side
After making a deep mark on one side of the plexiglass, grab the paper from the sides and flip it over, then pass the cutter along the same line you engraved on the other side. Repeat until you form a deep mark in the paper.
When you grab the paper, be careful that it does not bend or warp before the time has come to split it
Step 5. Position the paper so that the engraved part hangs over the edge of the table
Once you have finished engraving the sheet, move it to a position that makes it easier for you to split it, i.e. with the part you intend to detach over the edge of the work surface.
Make sure the entire section you intend to break extends over the edge of the table
Step 6. Secure the sheet to the table surface
Take some springs or C-clamps and use them to secure the part of the plexiglass sheet you don't intend to cut to the surface of the countertop so it can't move.
Be careful not to over tighten the clamps or you may leave marks on the plexiglass
Step 7. Peel off the engraved part of the plexiglass
With the plexiglass sheet stuck on the work surface, give a sharp downward blow to break the piece you engraved; the paper should break sharply along the line you marked.
- You can hold the sheet steady with one hand while using the other to apply pressure.
- If the plexiglass does not break completely along the line you scored, use the utility knife to cut further along the mark until it breaks.
Method 2 of 3: Make Straight Cuts with a Circular Saw
Step 1. Use a circular saw with a blade that has tungsten carbide tips
Thicker sheets of plexiglass need to be cut with a saw. Make sure the blade teeth are evenly spaced, as well as the same shape and size, in order to get an even cut. A tungsten carbide tipped blade is strong enough to cut plexiglass without dust or debris getting into the air.
- A blade with fewer teeth will minimize the amount of dust or debris produced during the operation.
- You can also find blades specially designed for cutting plexiglass on the market.
Attention:
small fragments of plexiglass could get into your eyes and seriously injure you; always wear protective eyewear when making cuts.
Step 2. Place the paper on an easel
Place the plexiglass sheet on an easel, in order to be able to cut it while keeping it flat and stable. Use a ruler to draw a straight line on the paper; this line will be the guide of your cut, so make sure it is straight and visible.
Use a dry-erase marker so you can easily get rid of the marks if you need to make any changes
Step 3. Align the saw cut guide with the line you drew
Each circular saw has a pointer or notch that allows you to see where the blade is aligned. Place this guide in line with the mark you drew on the plexiglass sheet.
Make sure the sheet is stable; it must not move or wobble
Step 4. Set the saw to full speed before cutting
To create a straight, even cut, the saw blade must rotate at full speed before making contact with the plexiglass. Turn on the saw and let it rotate until it reaches full speed.
Cutting the sheet before the saw blade has reached full speed could cause the teeth to lock onto the sheet and create a jagged or uneven cut
Step 5. Push the saw slowly and smoothly along the plexiglass
Use the cutting guide and the line you drew to guide the saw through the sheet. Push it at a steady pace to keep it from jamming.
- If the saw jams or gets stuck, you may be pushing it too fast. Pause for a moment to let the blade pick up speed, then continue cutting.
- Make sure the halves are firmly attached to the stand so they don't fall to the ground when you finish cutting.
Method 3 of 3: Use a Jigsaw for Irregular Cuts
Step 1. Use a jigsaw to make curved cuts
A jigsaw looks a lot like a bandsaw, but is smaller and cuts in a vertical motion. This tool is used to make both straight and rounded cuts, so it's a good option when you need to cut a specific shape or circular piece in a sheet of plexiglass.
- To cut the plexiglass use an uncoated fine tooth blade.
- Always keep a few extra blades with you, in case you need to replace them while you are cutting.
Step 2. Place the plexiglass sheet on an easel
Use an easel as a work station so the paper will be stable as you cut it. Secure the paper so that it is secure and firm on the easel.
Before you start cutting, make sure the plexiglass doesn't move or wobble
Step 3. Mark the sheet with a dry marker to guide the cut
It is very important to have a guide to follow when using a jigsaw, especially if the shape you are cutting is curved or irregular. A jigsaw allows you to cut a shape of your choice, but you need to have a good track to use as a guide. Use a dry erase marker to create the outline of the shape you intend to cut.
A dry-erase marker makes it easier for you to remove the mark when you're done or if you need to edit it
Advise:
if you need to cut a template or shape, use a stencil or round object to draw a regular line more easily.
Step 4. Wear safety glasses to protect your eyes
Cutting a sheet of Plexiglass can fill the air with splinters and tiny particles that could damage your eyes if they get through. Before starting the cutting operation, wear a pair of safety glasses.
Make sure your glasses stay snug on your nose and are not in danger of falling out while you cut
Step 5. Make a hole to insert the jigsaw into the sheet
The jigsaw needs an opening to fit into the plexiglass sheet, so first take a drill and, with a sufficiently large masonry bit, make a hole for the blade to pass through. If you need to cut an irregular shape, drill more holes through the sheet at the tightest corners of the shape - this will help the jigsaw blade turn when it gets there.
If the jigsaw blade cannot make those turns easily, it could bend or break
Step 6. Insert the jigsaw blade into the hole and set it to full speed
Insert the blade into the hole you made in the sheet and turn on the jigsaw. The blade of this tool moves slower than that of a band saw or circular saw, so it must be brought up to full speed before starting to cut.
- If the blade is not at full speed when it comes into contact with the plexiglass it could get caught and bend or even break and damage the hacksaw itself.
- It is possible that the blade will break and injure you, so be very careful.
Step 7. Slowly push the jigsaw to cut the plexiglass
Apply steady pressure to prevent the jigsaw from jerking off the sheet. Follow the signs you have drawn carefully and slow down when there are curves. If you feel or feel that the blade is blocked or jammed, slow down and go back a little to allow it to regain power, then start pushing the hacksaw through the plexiglass again.
