Video How to Cut Plexiglas

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Commonly used as an inexpensive, lightweight substitute for glass, this acrylic plastic requires patience when cutting because of its proclivity to chip and melt.

Step 1: Measure the shape
Measure your shape with a tape measure or ruler and mark it with a pencil. New Plexiglas sheets are typically covered with protective paper. Try to leave as much paper as possible on the Plexiglas to minimize scratching.

Step 2: Prepare to cut the Plexiglas
Put on your safety goggles and gloves. Use the scoring knife to lightly score along your cutting lines.

Tip
Plexiglas shards can cut just like glass. Be sure to wear the proper shoes and sweep up the work area when finished cutting.

Step 3: Score and break thin pieces
Score the Plexiglas where you want it to break, and then line the sheet up along the edge of a table with the scored side facing up. Sharply bend the Plexiglas down and snap it along the scored line.

Step 4: Cut with a saw
Use a table saw or band saw when cutting through Plexiglas that’s more than ¼-inch thick. Clamp down the Plexiglas to prevent slippage.

Tip
Consider using special Plexiglas-cutting blades for your table, circular, or band saw, available at your local hardware store. The blades have many fine teeth and will minimize chipping, cracking, and melting.

Step 5: Sand the edges
Sand the edges of your Plexiglas when you're finished cutting. Use fine grain sandpaper for a smooth finish.

Did You Know?
World War II warplanes were outfitted with Plexiglas cockpits, windows, and gunner turrets.