How to Cut Plexiglass

When it comes to cutting plexiglass, you need to be extra careful to avoid wastage. You will find that as you cut it, it becomes easy to tear it, and the thinner it is, the more easily it tears. While care and skill play a role in minimizing wastage, the tools you use also play an important role the quality of the finished product. In this article, we are going to look at some of the factors to consider when cutting plexiglass.

Cutting Methods

There are three methods that you can follow when cutting plexiglass. The methods are determined by the thickness of the plexiglass you are cutting. The rule of thumb is to cut thick material by scoring. That will ensure that you will get a clean and straight edge cut. If you are cutting a plexiglass with intermediate thickness, it best to use a saw. The freud saw blades can cut plexiglass, that’s because they have smaller, and closer teeth. The higher number of teeth per inches always gives a smoother cut. On the other hand, if the saw material is extremely thin, then you should use tools used for cutting plastic. Moreover, you should not try to cut the material fast; instead, you should do it slowly.


These methods work because the material is thick enough to bear the mechanical forces exerted on it without cracking. The first step is to use a metal ruler to get a solid edge along the point you many to cut. You then need to get a new blade and draw a line along the edge created by the metal ruler. You then need to repeat the procedure multiple times, until you create a score that’s deep enough. Next, you need to move the plexiglass to the edge of your work-surface and align the scored line positioned over the edge. Finally, you need to firmly hold it down on the work-surface, and then bring your other hand on the overhanging section you want to cut off. The plexiglass will break evenly along that line.


When sawing, use a freud saw with fine blade, and cut the plexiglass while making small angles. Moreover, the saw’s cutting stroke should be the one where you draw it towards you. That will allow you to follow and align it cutting motion in order to get a clean cut. Once you finish cutting, you should make a point of smoothing the edges with a fine emery paper. Using a saw with fewer teeth per inch will make it hard to get a finely cut edge.

Cutting Tool

If the plexiglass is too flexible for you to cut or saw, your option is to use a handheld rotary tool that also has a cut-off wheel. To make the cut, you should clamp the work-piece on a working surface and leave some space beneath the surface you intend to cut. Next, switch on your cutting tool, and maintain its speed to between 10,000 rpm to 15,000 rpm. That will provide you with a cleaner and straight cut. Here is miter saw buying guide to find the best type of a tool for this. Once done, you should fine-grit it using a rotary tool.

We hope that you found this article to be informative, and you will have a great time working on your plexiglass.

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