cuting plexi
 

what is the most efficient way to cut plexi-glass

Re: cuting plexi
 

A table saw with a non-ferrous blade.

After that, a jig saw with some lubricant
to avoid melting from the friction.

Eugene

Re: cuting plexi
 

A band saw works too.

Re: cuting plexi
 

If it's really thin plexiglas, I think you can score it and then carefully snap it. Look it up on google for more instructions.

Re: cuting plexi
 

The same blades you use for wood will work well but, you can buy specialty bits to cut plexi which work really nicely.

Re: cuting plexi
 

depends how much you care.

a carbide table saw blade works great for making strips.

metal bandsaw blade nice and slow works.

if milling it use a little coolant. just regular 40:1 mixture

if its polycarbonate scoring may not work

Re: cuting plexi
 

If it's polycarbonate, you can use a jump press (I've only ever cut 1/16" thick polycarbonate on a jump press, I'm not sure how much thicker you can get before it doesn't work as well.

Re: cuting plexi
 

I suggest with a properly applied cutting implement.

I'd love to help, but we need a bit more info. What thickness? What kind of cuts? What type of Plexiglass, or is this actually Polycarbonate/Acrylic?

Re: cuting plexi
 

My Favorite way to cut plexiglass is with a table saw. I've done it with a vertical bandsaw and a guide to keep it straight but the plexiglass may crack if it gets too jumpy.

As for Lexan (Polycarb), a Table Saw is still best for Straight cuts and I Like a vertical band saw the best for any kind of a technical cut.

If you're in a pinch and you need to cut Lexan (polycarb) you can use a Circular Saw. I'd only cut this way as a last resort because it gets pretty dangerous.

Re: cuting plexi
 

If it is thin, like 1/16 or smaller, shears work. They are slow but very straight.

Re: cuting plexi
 

Also, leave the paper backing on it while you're cutting it!!!!
This is important to avoid cracking/splintering for whatever method you use to cut it if you're using a saw type method.

If you're using a heated up piece of wire (which is possible for both cutting & bending - on a very low heat setting to avoid burning too much), then it would probably be better to take the paper off first.

Re: cuting plexi
 

Leave the film on the plexi glass, use a small tooth ratio blade, and also cut slowly so it will not fuse back together.

Re: cuting plexi
 

Don't use a hand saw. I had to do that at a regional once and it was not a good idea.

Also, when you cut plexi with a power blade. Realize that the plexi will send off little fragments of the glass. Might be a good idea to have sleeves on when cutting. (Just make sure the sleeves can't get caught or anything.)

Re: cuting plexi
 

We have been using jigsaws. Not the best, but they work. Gotta use coarse blades though, or else you will have melting problems.

Re: cuting plexi
 

A foot shear works well for 1/8" and thinner polycarbonate.
For thicker polycarb, a circular saw goes fast, but it splinters like mad.

Re: cuting plexi
 

Although it has been hinted at in this thread, I wanted to be sure that you knew that Plexiglas is different than polycarbonate.

I know that the difference may appear to be semantic to us electrical types but it is important. If you hit Plexiglass with a hammer it will violently shatter whereas polycarbonate is so resilient that it is used in most saftey glasses you and your team wear in the pits...

The impact resistance of polycarbonate extends to tooling as well. Polycarbonate can be cut in a sheet metal shear, bent on a brake and drilled or machined easily. Plexiglas is not nearly as machinable.

My team always uses polycarbonate on our robots and we never use Plexiglass. This not only gives us a more robust robot but also increases the safety margin for the students working on the robot.

JMHO

Mike

Re: cuting plexi
 

And a tip on drilling - you can break the leading edges on the bit to prevent them from digging in and grabbing. See http://www.hawkfish.org/snailman/acrdrill.htm If you can find the untwisted drill bits that are used in the Yankee type push drills, they serve a similar purpose. This also works for brass.

A few drops of water with liquid dishwashing detergent in it will help as well.

Re: cuting plexi
 

Mike I totally agree. I would never use plexiglas anywhere in my robot. I can get all I want for free but we still chose to purchase polycarbonate instead.

My company sells supplies for sign making. The reason I can get plexi free is because it is easily damaged in shipping and we always have the damaged pieces saved in our damaged goods rack. You won't find any polycarbonate in that rack.

Re: cuting plexi
 

In a bind, Team 975 once used some of the "high strength" Acrylic. It was only moderately more durable than the regular stuff. No comparison to polycarbonate.

Re: cuting plexi
 

Other than the table saw type stuff, we use a dremel with a spiral cutting bit (actually a Roto-Zip bit), with a straight-edge clamped to the material as a guide. Works very well.

BTW, don't inhale the fumes! Ventilate! :eek:

Cheers,
-Neil.

Re: cuting plexi
 

We always use polycarbonate and always use our bansaw when cutting it. Anything else is much more of a pain the only thing are the little shreds that you have to deal with but if you make sure to keep your mouth closed and of course your safety glasses on (probably semi-long sleeves too) and you should be fine. You grow used to it. Good luck.

Re: cuting plexi
 

I've found that using a dremmel with a high speed plastic cutting bit works really well, as long as you have a steady hand.

it's also nice since it lets you carve complex shapes.

be careful though, the fragments sent off from the dremmel are EXTREMELY HOT, and if you aren't careful, your arms get covered in little red dots from the burning plastic.

also, WEAR SAFETY GLASSES, they will save your eyes.

-Z

Re: cuting plexi
 

What we do: Big/straight cuts-Table Saw
Not possible to cut on a table saw-Band Saw
Too technical for either-Dremel, very slowly.

Re: cuting plexi
 

As everyone has said, leave the film on it. Our team uses a band saw and a table saw to do it. Any detailing, such as rounding corners etc, are done with a dremel. Be sure not to overheat it so it doesn't melt. If at all possible, get some Lexan. If your using the plexi I am thinking of, then its an acrylic material. Lexan is a polycarbonate material that doesnt break very easily. We learned not to use acrylic the hard way. Good luck to you though!

Re: cuting plexi
 

Whatever you choose to do, do it very carefully!!!! I was working and unfortunately destroying plexiglass just the other day. You have to be very careful and gentle or it will break easily. I tried drilling a piece and cracked it, then was cutting another and managed to crack it,too. I was embarassed, and felt bad about ruining it. I won't be working with it anytime soon..... Good luck, though.

Re: cuting plexi
 

Next time use polycarbonate (Lexan). It won't crack unless you spill Loctite or acetone on it.

Re: cuting plexi
 

I'm not sure what kind it was, but i didn't know it was so breakable. I tried to drill it without a guide hole, and it cracked. so we got more, and i was finishing the cut, and somehow managed to crack it again, even though I was being really careful. and the covering was on it.

Re: cuting plexi
 

Just use a jig saw and stay proud of your final cut line. Then use a hand held router with a bottom mounted bearing and clamp the plexi/polycarb to a straight edged countertop and trim it to final size. This easily works up to 1/2 inch thick if your router bit is large enough in diameter. We do this all day at work.

Re: cuting plexi
 

this is the first thing a tell any rookie team

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Fast moving, fine tooth blade. Band saw is what we have used, we have also had luck with a circular saw.

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We were hauling a piece of lexan into the new building (4x8) and we thought hmmm. lets test something. Secured a 0.5" thick scarp piece to it, went inside and asked a worker to drop a piece of rebar from the 3rd story. Didnt phase the lexan.

Re: cuting plexi
 

I like doing a demo where I clamp 1/4" thick pieces of acrylic and polycarbonate to a work bench and wail on them them both with a medium sized hammer. The acrylic shatters into smithereens while the polycarbonate dents slightly (if you hit it just right on an edge). I think it gets the point across. :)

-Vivek