How to Cut Plexiglass?

Plexiglass or acrylic are basically the same terms for polymethyl methacrylate (PMMA). The only difference is that the word ‘Plexiglas’ (with a single ‘s’) is a trademarked name, whereas acrylic is the generic name. We use it to refer to all acrylic plastics out there.

Though Plexiglass has transparency similar to glass, its remarkable properties are being non-brittle and lightweight. That’s why it has become an artisan’s favorite material for craft projects (artwork, jewelry, and illuminated décor). 

Cutting Plexiglass can be challenging because of its scratch-prone nature. But you don’t have to worry! This article explains the five common methods for cutting plexiglass, with detailed steps. By the end, you’ll know exactly which technique works best for your needs. 

Method 1: Cutting Plexiglass with A Laser Cutter

This one’s the modern and the simplest of all methods. You can cut any type of shapes and patterns out of plexiglass, and even engraving is possible – all that with minimal human effort.

In this method, you feed in a Plexiglass sheet in the laser and provide it with a design. The laser head (a sharp intense beam of light) moves across the cutting path and precisely makes all intricate cuts. 

The exact cuttable thickness depends on the power and nature of the laser machine. 

What Laser Cutter to use for cutting Plexiglass? 

Plexiglass can be cut using both diode and CO2 lasers, but there’s a catch. Powerful diode laser cutters (like the xTool S1) can only cut through colored or opaque plexiglass because clear ones don't absorb diode laser wavelengths. 

For Plexiglass, CO2 laser cutters are the best choice. Their 10,600 nm wavelength is absorbed by all plexiglass types, including clear ones. If you’re looking for a recommendation in this segment, xTool P2 is the best CO2 laser cutter available on the market. It has a 55W laser module, which is capable of making precise cuts and detailed engravings on all plexiglass sheets.

How to Cut Plexiglass with A Laser Cutter (xTool P2)?

After getting a laser cutter, here’s the process to follow for cutting Plexiglass. 

Step 1: Setup the machine and Material

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Set up the laser machine, making sure you’ve installed the inline duct to vent out fumes. Next, place the Plexiglass sheet on the bed with the protective film intact to avoid any scratches. 

Step 2: Import the Design File

Open xTool Creative Space (XCS) software and upload your design in SVG format. Use the machine’s dual-camera feature to position your design accurately on the material. Drag it to ensure it fits within the sheet and avoids previously cut areas.

Step 3: Customize Laser Cutting and Engraving (Optional) Settings

Select the material type. From the xTool material library on the sidebar, choose the material and thickness. On selection, the software automatically recommends cutting settings for the material, which can be further customized. 

In this case, we have set the parameters as 100% power, 20 speed, and 1 pass for clean cuts. For engravings (if any), adjust power at 15% and speed 300.  

Step 4: Begin the Cutting Process

Confirm your settings and start the laser cutter. The machine will engrave first, then cut the outline and any holes. 

Step 5: Final Touches

Once the process is complete and the machine beeps, remove the cut pieces. If you want to paint the engraved areas, use a paint pen while the protective film is still on, then peel it off to reveal the final look.

Method 2: Cutting Plexiglass by Hand Tools

Hand tools like utility knives are another quick method for making cuts into plexiglass sheets. The cutting pattern is similar to how glass is cut via blade – The lines are marked via a sharp blade and the sheet is bent. 

This method is limited to making straight cuts on acrylic. We often use it for dividing or splitting up an plexiglass sheet into smaller sections. Remember utility knives only work thin sheets (3 to 4mm). If you attempt to cut thicker, it can result in an injury.

Hand tools Needed for Cutting Plexiglass

• Utility knife
• Square / Straightedge

How to Cut Plexiglass by Hand?

With the two tools in hand, here’s the best course of action to cut the plexiglass:

Step 1: Prepare the Material

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Place the plexiglass sheet face-up on a stable surface. Keep the protective film on to prevent scratches. Then, use a square or straightedge to mark the line where the cut is needed.

Step 2: Score the Line

Position the square along the marked line and firmly press the utility knife against it. Carefully position your fingers away from the blade. Score the line multiple times using consistent pressure. Each successive movement removes a very thin layer of material.

Step 3: Break the Sheet

Once the line is deeply scored, place the sheet on the edge of a table with the scored line slightly overhanging. Apply steady downward pressure to snap the sheet along the line. In most cases, just flipping and bending from edges, also separates the two pieces.

Step 4: Sand the Edges

Being a manual method, carried out by successive marking lines, the cutting edges are not smooth. So, you’ll need to use sandpaper to smooth any rough edges for a cleaner finish.

Method 3: Cutting Plexiglass with Dremel

A Dremel is a powered hand tool that is often used for engraving Plexiglass but it can also cut with disc bits. It works well for making curved or irregular cuts, which are harder to achieve with other manual tools. Due to its small size, it can perform detailed work, provided you’re skilled to use it.

Tool and Supplies Needed

• Dremel 670 with cutting disk
• Wood Sheet
• Gloves, Safety Goggles
• Clamps

How to cut Plexiglass with a Dremel?

In order to use Dremel for cutting plexiglass precisely, we recommend following our steps:

Step 1: Mark the Design

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Use a marker or a utility knife to draw the design or cutting lines on the plexiglass sheet. These can be straight lines or custom patterns depending on your project.

Step 2: Spread Water

Apply a thin layer of water over the cutting area or use a damp cloth to cool the material during the cutting process. This helps reduce heat buildup and prevents the plexiglass from melting.

Step 3: Prepare Yourself and the Workspace

Wear safety goggles and gloves to protect yourself from plexiglass splinters.

Clamp the plexiglass sheet on a stable surface, like a thin piece of wood, to avoid cutting through the table accidentally. Alternatively, you can let the plexiglass protrude slightly over the edge of the table.

Step 4: Set the Speed and Cut

Adjust the Dremel to a low to medium speed (5000 rpm) to maintain control and avoid overheating the material. Hold the Dremel firmly and guide it along the marked lines. 

Method 4: Cutting Plexiglass With A Jigsaw

A jigsaw is a powerful tool for making curved and angled cuts, especially on wood. It provides much cleaner cuts than hand tools, though light sanding may still be needed afterward. Like most methods on our list, it also works only on thin plexiglass sheets (between 2 to 4mm).

To cut plexiglass with a jigsaw, use an uncoated fine-toothed blade designed for plastics. Standard wood-cutting blades are unsuitable and may damage the material.

If your jigsaw has an orbital motion setting, turn it off to avoid cracks or chips during cutting. Moreover, set the speed to low to maintain control and prevent overheating.

Tool Needed

• Jigsaw
• Drilling Machine
• Clamps
• Safety Gloves

How to cut Plexiglass with a Jiasaw?

With jigsaw, you’ve to be very careful. For better results, stick to these best practices:

Step 1: Prepare the Workspace and Materials

Place the plexiglass sheet on a flat, stable surface. Secure it with clamps, so it doesn’t vibrate while being cut. You should also wear safety gloves while cutting. 

For cutting, insert a fine-toothed blade, specifically designed for plastics. Avoid wood-cutting blades, as they can chip or crack the plexiglass.

Step 2: Mark the Cutting Line

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With a marker, draw the desired cutting line/pattern on the protective film of the plexiglass. If the film is missing, apply masking tape to the area to avoid scratches while marking.

Step 3: Drill Holes for Interior Cuts

If your design requires interior cuts (e.g., a shape within the sheet), drill a starting hole at the edge of the marked area. Use a drill with a bit size slightly larger than the jigsaw blade to create this opening.

Step 4: Cutting the Plexiglass

Turn off the pendular (orbital) motion of the jigsaw if it has one. And set the speeds to low or medium.  

If working on internal cuts, insert the jigsaw in the hole and guide it along the path. Else, you can navigate from the side, and make straight or angular cuts. Keep on spraying water while cutting to avoid overheating.

Method 5: Cutting Plexiglass with A Circular Saw

Circular saw is a commercially used tool for cutting wood, ceramic, and metals. Its sharp disc blade can easily cut significant thicknesses (above 4mm) of plexiglass. But for thin sheets (under 3mm), you’ll end up getting very rough edges. So, stick to the utility knife to cut such sheets. 

Circular saw is only limited to making straight cuts. You need to use a fine metal disc blade, designated for cutting plastics. It is one of the noisiest methods, which necessitates the use of noise protection.  

Tool Required

• Circular Saw
• Measuring Tape
• Safety Gear (Gloves and Noise Protection Headset)

How to Cut Plexiglass with a Circular Saw

Here’s what you need to do when cutting Plexiglas with a circular saw:

Step 1: Mark the Sheet and Clamp it

Use a measuring tape to determine the desired dimensions. Then, mark the cut line clearly on the protective film of the plexiglass using a marker.

Before you begin cutting, secure the plexiglass sheet with clamps. Maybe place a thin wood sheet underneath so you don’t accidentally damage the work table.

Step 2: Install the Blade and Adjust Settings

Choose an 80-tooth carbide-tipped blade suitable for plastics. Set the cutting speed based on the thickness of the plexiglass. Medium speed is best to avoid overheating.

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Step 3: Wear Safety Gear and Begin Cutting

Wear safety gloves and noise-cancellation headsets. Align the saw blade with the marked cut line. Spray water along the line or periodically do it while cutting.

Start the saw and allow it to reach its full speed before making contact with the plexiglass. Guide the saw steadily along the marked line, applying consistent pressure without forcing the blade.

Step 4: Finishing

After completing the cut, inspect the edges for any roughness. Use fine-grit sandpaper to smooth out any imperfections. 

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Conclusion

That wraps up our list of methods for cutting plexiglass. We have covered both manual techniques (using mechanical hand tools and powered tools) and automatic options. For crafting and intricate designs, laser cutting emerges as the easiest and most accessible method that everyone can try.

FAQs Related to Cutting Plexiglass

What is the easiest way to cut plexiglass?

The easiest way, requiring no manual skills or extra safety equipment, is using a laser cutting machine. You simply load the sheet and design, and the laser follows the path to make the cut automatically.

How thick plexiglass you can cut with a laser?

The thickness depends on the laser type and power. A 40W diode laser, like the xTool S1, cuts up to 15mm opaque plexiglass in one pass, while a 55W CO2 laser can cut sheets up to 20mm thick in one pass.

What’s the best way to cut plexiglass without cracking it?

Laser cutting is the most effective method to prevent cracking. Unlike mechanical tools, it uses a focused laser beam that precisely penetrates and removes material without applying physical pressure.

How to cut plexiglass cleanly?

For clean cuts, always use sharp blades specifically designed for plexiglass to avoid chipping. When using power tools like a jigsaw or circular saw, spray water over the cutting area to reduce heat buildup, avoiding plexiglass melting or rough edges.