cuting plexi

[Pumagrif]

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

[Molten]

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.)

[BurtGummer]

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

[NickE]

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

[ZInventor]

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

[millerm277]

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.

[NC GEARS]

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!

[Carlee10]

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.

[artdutra04]

Originally Posted by Water Bandit23

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.

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

[Carlee10]

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.

[Dave Morris]

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.

[Team 135]

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

[charlie1218]

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.

[vivek16]

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