Ways to Successfully Cut Plexiglass

How to Cut Plexiglass with a Utility Knife

Cutting plexiglass with a utility knife works best for making straight cuts in thin sheets of plexiglass (1/8 inch or less). But while a utility knife is convenient (you probably have one in your tool kit), Bolden does not love this method. “A sharp razor blade easily wanders across the surface of the materials,” she says. “Once [it] veers away from the straight edge, the plexiglass will not snap cleanly or straight.”

• Take the straight edge of your ruler and mark where you’d like to cut with a permanent marker.
• Place the plexiglass on a clean, sturdy work surface.
• Clamp a straightedge onto the plexiglass at the marked line.
• Wear utility gloves and safety glasses.
• Repeatedly score the plexiglass along the straightedge with steady pressure.
• Release the clamps and remove the plexiglass.
• Place the scored line of the plexiglass over a table edge.
• While holding the sheet firmly against the tabletop, apply downward pressure to the overhanging plexiglass until it snaps at the line.
• Clean up any rough edges with 120-grit sandpaper.

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How to Cut Plexiglass with a Jigsaw

Equip a jigsaw with a blade designed to cut plexiglass for a simple and fast way to make cuts. This method is great for making curved and straight cuts in thick and thin plexiglass. Bolden recommends using a “specialty blade with a minimum of 13 teeth-per-inch (TPI).” In addition, support the plexiglass from underneath on both sides of the cut for best results.

• Clamp the plexiglass to a 1/2-inch thick piece of plywood to reduce vibration when cutting.
• Clamp the plywood and plexiglass to a solid work surface. Overhang the cut line over the edge of the table.
• Wear safety glasses, gloves and hearing protection.
• Cut the plexiglass and plywood with the jigsaw along the marked line.
• Use sandpaper to clean up any rough edges.

How to Cut Plexiglass with a Circular Saw

To make cuts with a circular saw, you will need a specialty blade. Bolden recommends a carbide blade with at least 60 TPI. This method works well for making straight cuts in plexiglass of varying thicknesses. “For ideal results, the workpiece needs to be supported underneath both sides of the plexiglass to prevent excessive vibration,” Bolden adds.

• Clamp the plexiglass to a piece of 1/2-in. plywood to provide full support.
• Clamp the plywood and plexiglass to a solid work surface. Overhang the cut line over the edge of the table.
• Wear safety glasses, gloves and hearing protection.
• Allow the saw to get up to full speed, then cut the plexiglass along the marked line.
• Use sandpaper to clean up any rough edges.

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How to Cut Plexiglass with a Table Saw

A table saw can be an effective way to complete straight cuts in thin and thick pieces of plexiglass. For best results, Bolden recommends using a zero clearance insert on your saw to support the piece evenly when cutting. Use a specialty blade with a minimum of 60 TPI. “When cutting thinner pieces of plexiglass on a table saw, one can cover or sandwich the plexiglass with a sacrificial piece of wood to cut down on vibration,” Bolden says.

• Set the blade height so it is slightly higher than the thickness of the piece being cut.
• Insert a zero clearance insert (if you have one).
• Wear safety glasses, gloves and hearing protection.
• Set the adjustable fence along the plexiglass edge.
• For thicker pieces, guide the plexiglass through the saw blade to cut. Use a push stick or block to move the piece and finish the cut.
• For thinner pieces, place a board over the plexiglass. Adjust the blade for the added thickness, then run both pieces through the saw.
• Use sandpaper to clean up any rough edges.

How to Cut Plexiglass with a Scoring Tool

While designed to cut plexiglass, scoring tools are marginally effective with very thin pieces (1/8-inch or less). “Scoring tools are really hard to use,” Shulka says. “It’s difficult to apply enough pressure to actually make a cut, and you need to score it over and over again.”

• To cut plexiglass with a scoring tool, you’ll want to follow the steps outlined above for cutting plexiglass with a utility knife. The method and steps are the same, you’ll just be using a scoring tool rather than a utility knife.

How to Cut Plexiglass with a Hacksaw

This method works best to make straight cuts in thicker pieces of plexiglass that maintain rigidity.

• Mark your cut line with a straight edge.
• Clamp the piece to a work surface, with the cut line slightly overhanging the edge.
• Wear safety gloves and glasses.
• With the saw at a shallow angle, move the saw back and forth to establish a cut.
• Continue cutting with the hacksaw until complete.
• Clean up any rough edges with sandpaper.

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How to Cut Plexiglass with an Oscillating Tool

To complete curved and straight cuts, you can also use an oscillating tool. This method works best with thin pieces (1/8-inch or less). Use a half-moon-shaped blade with fine teeth.

• Support the plexiglass with a piece of 1/2-in. plywood, then clamp both to a solid work surface.
• Clamp a straightedge onto the plexiglass where the cut will be made.
• Following the straightedge, score the surface with the oscillating tool blade. The blade can easily veer off, so work slowly.
• Make several more passes, following the original scoreline.
• You can cut it completely through for thinner pieces, or score several times then snap.
• Use sandpaper to clean up any rough edges.

Pro-tip: This method can leave ridges of melted plexiglass along the cut. Wait until these ridges cool, then snap them off and sand to finish.

How to Cut Plexiglass with a Multi-Material Cutter

If you cut plexiglass regularly, consider using a multi-material cutter for straight cuts. These tools consist of a stainless steel blade affixed to a moveable track. Available as wall-mounted or tabletop models, this is the tool Shulka primarily uses to complete lots of clean, straight cuts each day.

• Use a straightedge and mark where you’d like to cut with a permanent marker.
• Place the plexiglass on the platform or tray, depending on the tool type.
• Position the material under the blade at the cut line.
• Grasp the blade handle and pull it across the plexiglass to score it.
• “Score it several times, increasing pressure as you go,” Shulka says.
• Remove the piece and place it over the edge of a table, then snap it at the scored line.

FAQ

What is the best way to cut plexiglass, and why?

According to Bolden, using a jigsaw fitted with a specialty blade is the best way to cut plexiglass. This method is a fast, easy way to cut straight and curved cuts in plexiglass of varying thicknesses.

How do you prevent cracking when cutting plexiglass?

• If using scoring tools, score it deeply and repeatedly before trying to snap plexiglass. “If you don’t score plexiglass enough, it won’t break cleanly,” Shulka says.
• Measure carefully. It’s difficult to trim a little bit off acrylic. Often, if the piece is just a bit oversized “you have to start over with a new piece, or you run the risk of cracking it,” Shulka says.
• Firmly clamp the piece while cutting.
• When cutting with a power tool, always use a blade with the appropriate TPI.

About the Experts

• Leah Bolden is one of the top home improvement authorities in the country. She’s appeared on the History Channel, has a social media following of 1.3 million and has been invited to the White House due to her home improvement expertise on social media. Find Leah on YouTube’s See Jane Drill channel.
• Lisa Shulka is a custom picture framer at Hope and Feathers Framing in Northampton, Massachusetts. She has 30 years of framing experience.