By Bob Vila | Updated Apr 30, 2021 1:20 PM
In a range of applications, from picture frames to tabletops, plexiglass (also known as acrylic) serves as a cost-effective, shatterproof substitute for glass. In fact, due to its light weight and durability, many do-it-yourselfers prefer plexiglass, not least because it can be cut and shaped with common workshop tools.
Versatile and tough though it may be, plexiglass isn’t perfect. For one thing, it scratches easily. That’s why sheets of the material come covered in a thin layer of protective film. The other downside? Homeowners who don’t know how to cut plexiglass can be intimidated by the material at first—but we’re here to help!
When cutting plexiglass, leave the film in place as long as possible to avoid marring the surface. Second, bear in mind that even if you’re careful, it can be difficult to cut plexiglass without leaving a rough, irregular edge. If your project requires a clean edge, expect to devote energy to smoothing the finish. Simply cutting plexiglass to size is easy by comparison.
Continue reading for details on how to cut plexiglass—the right way.
For a thin sheet of plexiglass—that is, material up to about 3/16-inch thick—use a scoring method not dissimilar from a technique used to cut actual glass.
RELATED: How to Clean Plexiglass
For thicker sheets of plexiglass, cut with a power saw—be it a circular saw, saber saw, or table saw. (To cut anything but a straight line, opt for a jigsaw.)
No matter which type of saw you choose for the task, it’s critically important to use the right blade. There are special blades designed expressly for acrylic, but any metal-cutting blade with carbide tips can do the trick. Before committing to one blade or another, double-check that its teeth are evenly spaced, with no rake, and of uniform height and shape.
After readying your tool, measure and mark the plexiglass, then cut as you would any other material, clamping if appropriate. One note of caution: If the blade overheats, the material may chip or crack. Proceed accordingly, water-cooling the blade or pausing your work for a few minutes as needed.
Whichever cutting method you choose, you may find that the cut plexiglass edge doesn’t look terribly attractive. If the cut edge would be visible in your application, take the extra time to sand and buff out the imperfections. Note: You can use a handheld power sander, but manual wet-sanding typically achieves the best results.
Though plexiglass is a durable material, it’s not unbreakable. Keep the following tips in mind when learning how to cut plexiglass to prevent irreversible damages.
RELATED: How to Cut Plastic
Every building material comes with a set of quirks and nuances that you can master with practice. Fortunately, it doesn’t take long for do-it-yourselfers with woodworking experience to learn how to cut plexiglass.
Although for the time being, you may only need to cut a piece of acrylic down to size, learning to work with this versatile, transparent material opens up a new universe of DIY possibilities that you can explore in myriad projects for years to come.
Disclosure: BobVila.com participates in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for publishers to earn fees by linking to Amazon.com and affiliated sites.
Copyright © 2022 Acton Media Inc. All rights reserved.