You have probably heard of plexiglass somewhere, but you do not yet know what it is. Whether it concerns jigsaw plexiglass or circular saw plexiglass, these names refer to the same sheet. To clarify, it is important to provide a complete definition of plexiglass or plexiglas.
What is plexiglass?
Also called methyl methacrylate polymer or PMMA, plexiglass is a thermoplastic material. This means that the sheet becomes soft once it is heated. In most cases, it replaces glass because it has a high shock tolerance. Other experts call it Altuglas or Perpex.
This transparent material is used in multiple fields. It allows the manufacture of a large number of objects found in decoration, optics, or industry. It is notably known for making windows. Unlike glass, it is lighter.
Despite all its qualities, it is less resistant, therefore more fragile to work with. Plexiglass is likely to break more easily. Cutting it requires specific precautions. To carry it out successfully, it is important to equip yourself with the right tools.
What tools to cut plexiglass?
| Method | Recommended thickness | Necessary tools | Key steps | Practical tips |
|---|---|---|---|---|
| Utility knife (scoring technique) | Up to 3 mm | Straight blade utility knife, metal ruler | Score several times with pressure, then snap cleanly on the edge of a table | Ideal for small straight cuts |
| Jigsaw | 3 to 15 mm | Jigsaw, fine blade with fine teeth | Secure the plexiglass, cut slowly while holding the sheet firmly | Use adhesive tape on the line to avoid chipping |
| Circular saw | > 5 mm | Circular saw, special carbide blade | Mark, secure the plexiglass, cut slowly and steadily | Hold well to avoid vibrations |
| Dremel or rotary tool | Thin pieces or shapes | Dremel + cutting disc | Work in small sections, at medium speed | Ideal for curved shapes or details |
| Laser (professional) | All thicknesses | Laser cutting machine | Vector file + suitable machine | Extreme precision, clean finish, professional use only |
Depending on the style and shape of the sheet, there is a wide variety of devices used to work on these sheets. If you wonder how to cut plexiglass, the choice of equipment depends on the nature of the expected result and the thickness of the plexiglass.
- An angle grinder
Versatile, it is not only used for grinding, sanding, or polishing, but also for cutting plexiglass sheets. Thanks to its diamond disc, it allows clean and neat cuts without visible marks. - A router
Often associated with woodworking, it can also be used to cut plexiglass precisely. It is essential to hold the material well during the operation and to use a CMT bit for a cleaner finish. - A utility knife
A very common tool for cutting plexiglass. It is used both for initial cuts and for removing sharp edges during finishing. Choose a well-sharpened blade for better results. - A circular saw
To cut plexiglass with a circular saw, it is recommended to use a new blade. Models like the GKS or RPM circular saw are often favored for their straight and clean cuts. - A jigsaw
Resembling a band saw, the jigsaw is one of the most popular tools for working with plexiglass. For a clean cut, use a clamp and a special blade for plexiglass.
Which blade to use for cutting plexiglass?
To cut plexiglass with a saw, it is crucial to work with a good blade. Whether you use a utility knife, an electric circular saw, or a jigsaw, the important thing is to use a well-sharpened blade. It allows you to achieve better results when cutting plexiglass.
If you use a low-quality saw blade, your tool will only chew up the sheets. It cuts the panel imprecisely. It is better to opt for a high-quality piece, even if it is often a bit expensive. It is advisable to check the blade price information beforehand before making your choice.
If you use a circular saw, there is a special blade adapted to this device for cutting plexiglass. It is a blade with alternating and beveled teeth. For a jigsaw blade, a steel one is highly recommended.
According to experts, a 10 TPI bimetal decoration blade is a good option. Others prefer an ultra-sharp hollow floor wood blade. Whatever your choice, it is advised to remove from your list the very fine metal jigsaw blade. It often tends to clog during work, causing the plexiglass to melt.
How to cut thin plexiglass?
If you want to know how to cut thin plexiglass, the utility knife is the most commonly used tool. To use it, first prepare your work surface by dusting it off. Use a fine marker to mark the cutting line on the protective film. Score the plexiglass along the line you just drew using a utility knife or a ruler. It is preferable to handle the tool’s blade upside down to avoid making a bad mark. Make at least 5 passes with the utility knife on both sides of the plexiglass sheet.
Once done, place the material again on the workbench or table to proceed with the cut. Try to position the cutting line 1 cm from the edge of the work surface. After cutting, remove the plastic film and clean your work surface.
How to cut thick plexiglass?
If you plan to cut plexiglass thicker than 5mm, the utility knife is not suitable for this job. You need a more efficient tool like the jigsaw. The process of cutting plexiglass with a jigsaw is not as complicated as one might think.
Just like working with thin plexiglass, it is necessary to mark the cutting line with a marker. Masking tape is very useful to prevent possible chipping. That said, you can install a jigsaw blade at the right speed. Once fixed, proceed to cut your plexiglass. To better regularize the cut and angles, use a utility knife. The last step is to remove the plastic film from both sides of the plexiglass sheet.
How to drill plexiglass without breaking it?
No matter the thickness of the plexiglass, it is important to emphasize that this material tends to crack easily. Therefore, its cutting requires some precautions to prevent breakage.
One of the most well-known tips is that a layer of masking tape helps avoid chipping. Circular saw rpm, professional circular saw or jigsaw, your tool has no difficulty cutting through it to the same extent as it cuts the plexiglass.
The use of water is also effective to avoid breaking the sheet. You can slightly moisten the plexiglass depending on its heat. It is also possible to add water to the blade to keep it cool.
Besides that, you can apply a cooling lubricant which is available in specialized stores. Choose a non-flammable product that is suitable for plexiglass. Thanks to it, your saw also moves with ease.
How to cut plexiglass of 5mm, 6mm, 8mm, and 10mm?
When the plexiglass thickness exceeds 5 mm, the use of an electric saw is necessary. Generally, DIYers use the circular saw and the jigsaw, but the latter is especially favored.
Before starting, place the sheet on a clean work surface. Draw a straight line to serve as a guide where you want to cut. Use masking tape on the line to limit chipping. Then install the metal saw blade on the device. Adjust its speed to a low level so as not to heat the material, otherwise, it will cause it to melt.
Now make the cut on the plexiglass and don’t forget to remove the masking tape. Be careful not to stop the saw while cutting; make the cut in one go. Otherwise, the plexiglass heats up and sticks to the blade. To finish, you can use a cutter blade or a mini router to obtain a regular and clean cut. Moreover, this tool allows you to deburr the edges. All that remains is to remove the protective film.
How to cut plexiglass cleanly?
First of all, cutting plexiglass with a saw requires a very clean work surface to work comfortably. Make sure to remove dust from the table saw before starting. During the operation, avoid removing the protective sheet covering the material even until installation. This transparent film is useful to prevent scratches. Do not hesitate to put adhesive tape on the part to be cut, as this will prevent chipping. In most cases, DIYers use masking tape. Once you finish cutting, use an electric planer to remove burrs. To ensure a perfect result, wipe the plexiglass with a cloth.
Besides all these tips, there is another approach that helps you cut this material cleanly. It involves using a laser guide. However, it must be admitted that this method is costly. If you want to try it, you can buy plexiglass sheets at a store equipped with it. They take care of laser cutting the material to the size you want.
A jigsaw is the perfect tool for making rounded cuts. Although it resembles the band saw, it differs in its roles. While it is capable of making straight cuts, curved shapes are among its specialties. To achieve this, it is recommended to use a fine-toothed hacksaw blade. This is suitable for this type of acrylic glass to successfully carry out the cutting work.
If you are dealing with large volumes of plexiglass, industrial cutting techniques save you a huge amount of time. But otherwise, a utility knife will do the job. It is perfect for making cuts on this material by hand. With a well-sharpened blade, you will get excellent results.
To do this, it is essential to equip yourself with a good quality jigsaw blade. A fine-toothed or uncoated blade provides precise cuts. Experts suggest beginners cut regularly with the jigsaw. Likewise, it is important to avoid stopping halfway through the cut. This type of saw is mainly used to create curved angles.
