How to Cut Plastic Sheets

How to Cut Plastic Sheets: A Guide for DIYers and Professionals

The best way to cut plastic sheets, like acrylic plexiglass sheets, requires the right tools and techniques to achieve clean and precise cuts. This guide will walk you through five different methods for cutting plastic, whether its plexiglass or polycarbonate, whether you’re doing it yourself or opting for professional cutting services at TAP Plastics.

Safety First

Before cutting plastic, always wear eye protection and ensure a stable work surface. Different types of plastic have unique properties, so some techniques may vary.

Five Methods for Cutting Plastic

1. Scribing and Breaking (Hand Cutting Method)

This method is suitable for cutting short lengths of plastic sheets up to 1/8-inch thick.

Steps:

  1. Place the plastic sheet on a flat surface and mark the cutting line.

  2. Use a straight edge to guide an acrylic scriber or sturdy knife.

  3. Scribe the sheet several times with firm, even pressure.

  4. Position the sheet so the scribed line extends just beyond the edge of a table.

  5. Hold the sheet firmly using a board or another piece of plastic.

  6. Apply sharp downward pressure to break the sheet cleanly along the scribed line.

2. Cutting with a Saber Saw (Jigsaw)

This method is ideal for cutting curved shapes.

Steps:

  1. Use a blade with about 10 teeth per inch, specifically designed for plastic.

  2. Place the plastic sheet on a thick piece of Styrofoam for support.

  3. If Styrofoam is not available, clamp the sheet to a table and use a top support piece.

  4. Cut as close to the table edge as possible to minimize vibration.

3. Cutting with a Band Saw

The band saw is effective for intricate cuts and handling thicker plastic sheets.

Steps:

  1. Use a blade about 1/2 inch wide with 14 teeth per inch.

  2. Feed the plastic into the blade similar to working with wood.

  3. Watch for melting issues, particularly with thicker plastic pieces.

4. Cutting with a Circular Saw

A circular saw is useful for straight cuts in thicker plastic sheets.

Steps:

  1. Use a carbide-tipped triple-chip tooth design blade.

  2. A plywood blade can be used but may cause melting.

  3. Support the sheet as shown in previous methods to prevent chipping.

5. Cutting with a Table Saw

The best method for straight cuts in plastic sheets.

Steps:

  1. Use a 10-inch blade with 60-80 teeth and a triple-chip design.

  2. Adjust the blade height to 1/8 to 1/2 inch above the plastic sheet.

  3. A blade set too high or too low can result in poor cuts and safety hazards.

Professional Cutting Services at TAP Plastics

If you prefer not to cut the plastic yourself, TAP Plastics offers a range of cutting services:

Example Application

One TAP Plastics customer needed a custom acrylic frame for a video conference display. Using a laser cutter, TAP Plastics produced a precise shape with added graphics for a professional finish.

Conclusion

Whether you need to make simple cuts or intricate designs, these cutting techniques will help you work with plastic sheets efficiently. For those who prefer expert precision, TAP Plastics offers cutting services to meet various needs.

Now that you understand how to cut plastic, you’re ready to tackle your next project with confidence!

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