TAP Article: How To Cut Plexiglass And Acrylic

How to Cut Plexiglass and Acrylic: Best Tips and Techniques

Plexiglass, also known as an acrylic sheet, is a durable and versatile material widely used in various applications. While it might seem like you need specialized machinery to cut plexiglass, that's not always the case. With the right household tools, even thin sheets of plexiglass can be easily cut for all kinds of projects. In this guide, we'll show you how to cut plexiglass and acrylic, ensuring you can make the most of this strong and flexible material.

Preparation Tips

Before diving into the cutting process, it's essential to choose the right method based on the thickness of your acrylic sheet:

  • Thick Acrylic Sheets: Best cut using the scoring method.
  • Medium Acrylic Sheets: A scroll saw is ideal.
  • Thin Acrylic Sheets: A handheld rotary tool works best.

To prevent damage, keep the protective masking on the plexiglass as long as possible. Cutting plexiglass can sometimes leave a rough edge, so be prepared to spend some time smoothing and polishing the edges if your project requires a clean finish.

How to Cut Plexiglass and Acrylic

Scoring Method (For Thick Acrylic Sheets)

Cutting thick acrylic sheets is surprisingly simple. Here’s how:

  1. Tools Needed: Metal ruler and a TAP Acrylic Knife with a fresh blade.
  2. Mark and Score: Place the ruler along the cutting line, and use the acrylic knife to score the sheet. Apply increasing pressure with each pass until you’ve created a deep groove.
  3. Repeat and Break: Flip the sheet over and repeat the scoring process on the other side. Position the plexiglass over the edge of a sturdy table, with the scored line aligned with the table's edge. Apply downward pressure until the sheet snaps cleanly along the groove.
  4. Safety Tip: If working with a large sheet, place something soft underneath to protect it from scratches when it breaks.

Sawing Method (For Medium Acrylic Sheets)

For medium-thickness acrylic sheets, a scroll saw is your best bet:

  1. Tool Selection: A scroll saw produces less heat, reducing the risk of melting the plexiglass. You can also use a table saw with a fine-toothed blade (at least 10 teeth per inch).
  2. Safety First: Wear goggles, gloves, and a long-sleeved shirt to protect yourself from flying debris.
  3. Cutting Technique: Position the plexiglass so the blade starts at the far end and moves toward you. Keep a spray bottle of water handy to cool the material if it heats up.

Cutting with a Rotary Tool (For Thin Acrylic Sheets)

For thin sheets, a handheld rotary tool will do the job:

  1. Setup: Secure the acrylic sheet to your work surface, with the cutting line marked clearly.
  2. Cutting Process: Set your rotary tool to operate between 10,000 and 15,000 RPM. Carefully cut along the marked line until the portion overhanging the table falls away.

Finishing the Cut

After cutting, your plexiglass edges will likely need some smoothing and polishing:

  1. Materials Needed: 120 to 600 grit wet-sanding sandpaper, a sanding block (wood or rubber), a power drill with a buffing pad attachment, and a plastic polishing compound.
  2. Sanding Process: Soak the sandpaper in water for at least 15 minutes. Start with 120 grit sandpaper, gradually working up to 600 grit as the edges become smoother.
  3. Polishing: Attach the buffing pad to your drill, apply the polishing compound, and buff the edges to a smooth finish.

Additional Resources

For more detailed instructions, check out our videos on “How to Cut Plastic Sheets” and “How to Polish and Shape Plastic.”

Conclusion

Cutting plexiglass and acrylic might seem daunting at first, but with the right tools and techniques, it’s a straightforward process. Now that you’re equipped with the knowledge, you can confidently tackle any project involving plexiglass. For all your acrylic needs, including cut-to-size sheets and polishing products, visit TAP Plastics. If you have any questions or need further assistance, don’t hesitate to reach out to us.