How to Cut Acrylic Sheet: 4 Ways Explained

Acrylic, also known as plexiglass, is a visually captivating material and finds use in a diverse array of products. Its availability in different colors and sizes makes acrylic a welcomed material for both DIYers and businesses to create varieties of projects for decoration or fashion.

Acrylic sheets are glossy and brittle in nature, and tend to break or scratch. Therefore, cutting acrylic sheets is no easy task. Manual tools can do the job, but the advant of laser cutting machines has brought a whole new experience for both individuals and businesses.

This article is aimed to recommend 4 best ways to cut acrylic sheets, helping both beginners in handicraft and the machine-savvy ones to quickly learn how to cut acrylic sheets. All the methods will be provided along with the tools you need.

Method 1: Cutting Acrylic Sheet by Hand

Acrylic sheets are hard to cut, and cutting them by hand is even harder.

However, if you don’t have any professional tool in hand, like jigsaw or laser cutting machine, non-machine acrylic cutting is still possible for some simple rough cutting. But this method only supports acrylic cutting along straight lines.

Tools Needed for Cutting Acrylic by Hand

• Scoring tool: It can be either a utility knife or a scoring blade.
• Rigid straight edge: Anything handy for measuring and marking is acceptable. You can use a rectangular tube or stick.
• Flat surface: The flat surface serves as a supporting platform for cutting. A flat table is a recommeded option.
• Clamp: Two clamps are needed to fixate acrylic sheets and rigid edges onto the flat surface. In that case, the acrylic sheet will not move during cutting.

How to Cut Acrylic by Hand?

After getting everything needed prepared, perform the following procedure.

Step 1: Measuring and Marking

Place the rigid straight edge you opt for on the acrylic sheet, and mark out the part you wish to cut off. 

©Cosador – YouTube

Step 2: Clamping

Line up the edge to the mark, and use the clamp to fix it on the acrylic sheet.

Step 3: Scoring

Run the blade closely next to the edge across the acrylic sheet. Remember to be firm but as well as gentle enough to avoid deviation of the blade.

Flip the sheet and line up the edge with the scoring mark. Then re-clamp the edge, and score this side of the sheet.

Step 4: Breaking

In this step, you should not break the sheet from the smaller side, as the pressing force may be uneven. Snap the larger piece of the acrylic sheet, and use even force carefully to push it downward, breaking it from the whole.

Then, the whole cutting process is done.

Method 2: Cutting Acrylic Sheet with Saw

The assistance of machines can definitely facilitate the cutting work. You can use a jigsaw or a table saw to smooth the process.

Cutting Acrylic Sheets with Jigsaw

The advantage of using a jigsaw is the ability to cut acrylic sheets with rounded corners and generate a clean cut.

However, cutting too slowly can melt the acrylic and applying too much pressure can cause the edges to chip. Using lubricating oil can help prevent melting, but take care to avoid flammable lubricants or aerosols as these are a fire hazard.

Tools Needed for Cutting Acrylic with Jigsaw

• Marker pen
• Masking tape
• Jigsaw
• Clamp
• Flat surface

How to Cut Acrylic Sheets with Jigsaw?

Step 1: Marking

Use the marker pen to mark the area you wish to cut.

©FERMTOOLBOXTV – YouTube

Step 2: Attaching masking tape

To cut acrylic without cracking, attach masking tape over the marking line. Then mark the line on the top of the tape.

Step 3: Setup and Practice with Dremel

Fix the acrylic sheet on the flat surface with a clamp. Use the hand to grab another end of the acrylic sheet.

Step 4: Cutting

Cut the acrylic according to the marking line with care and good control of the speed.

Cutting Acrylic Sheets with Table Saw

Compared with hand tools or other saws, table saw is handy and powerful enough for beginners to cut through thick acrylic sheets with ease. With the right blade, proper setup, and technique, a circular saw can deliver clean and straight cuts quickly.

Tools Needed for Cutting Acrylic Sheets with Table Saw

• Table saw
• Masking tape
• Rip fence
• Safety gear
• Flat surface

How to Cut Acrylic Sheets with Table Saw?

Step 1: Taping

To perform acrylic cutting without cracking, you are recommended to mask the area you want to cut with tape.

Step 2: Setting up the table saw

Choose a suitable blade for the saw and install it. Ensure the rip fence is aligned parallel to the blade for a straight cut.

Step 3: Cutting

Do the cutting along the marked line in slow motion with even and steady pressure. 

©Ryan Bauman (Plastics 2000) – YouTube

Step 4: Cleanup

After cutting, you can polish the edge with sandpaper, and then peel off the protective film on acrylic if needed.

Method 3: Cutting Acrylic Sheet with CNC Router

CNC routers can handle intricate shapes, curves, and patterns that would be challenging or impossible to achieve with other tools. When faced with complex designs, CNC routers are faster than saws and manual machines. Once the design is programmed, the cutting process is fully automated.

However, due to its direct contact with acrylic, CNC router will produce noise and plastic dust during the cutting process. 

Tools Needed for Cutting Acrylic Sheets with CNC Router

• CNC router
• Clamp
• Router bits
  
• Safety gear
• Flat surface

How to cut Acrylic Sheets with CNC Router?

Step 1: Preparing the acrylic sheet

Place the sheet on the CNC router bed, and use clamps to secure the acrylic to the flat surface.

Step 2: Configuring the CNC router

Select the right router bit. Single-flute up-cut bits are advised for cutting acrylic, and for thicker acrylic, a spiral bit with a cutting edge is better. Then set the cutting parameters as needed, like the feed rate and the depth of cut.

©Laguna Tools-YouTube

Step 3: Creating and Importing Design

Use CAD software to create your design, ensuring that the toolpaths are optimized for your CNC router. Then import the design in the compatible format into the control software.

Step 4: Cutting

Turn on the spindle and allow it to reach the programmed speed. Begin the cutting process and monitor the CNC router. 

Step 5: Post-Cut Finishing

Check the cut edges for smoothness. If necessary, you can sand or polish the edges.

Method 4: Cutting Acrylic Sheet with Laser

Laser cutting is a sought-after acrylic cutting choice. Different from CNC routing, laser cutting is a non-contact cutting method, thus producing clean and smooth cuts and avoiding the release of loads of waste like dust.  Laser cutters also provide frosted etching that creates beautiful contrast on clear acrylic when laser engraved. Besides, laser cutting is able to handle complex tasks beyond the capability of other manual tools. In terms of engraving, laser cutters can deliver impressive performance as well.

CO2 laser cutters and diode laser cutters can all perform acrylic cutting. Generally, diode laser cutters are designated for some dark opaque acrylic, while incapable of cutting clear acrylic. CO2 laser cutters support all types of acrylic.

CO2 laser cutters with efficient power, like xTool P2, stand out as the best acrylic laser cutter. It can cut through 20 mm acrylic in one pass with great precision and efficiency. Its wide material compatibility allows for cutting all varieties of materials, including acrylic. 

Among different diode laser cutters, xTool S1 will be a good option.Though being compatible only with dark opaque variants with regard to acrylic, xTool S1 comes off relatively cheaper and is more suitable for beginners. If you are a new comer in this area and just want to quickly get on with laser acrylic cutting, xTool S1 will not let you down.

Simply put, for those with more budget and willing to tap deeper into the area, xTool P2 is highly recommended. If you are not a practitioner in the business, and long for something cost-effective, just opt for xTool S1.

How to Laser Cut Acrylic?

Here's the step-by-step guide to help you get started acrylic laser cutting with machines like xTool P2 and xTool S1.

Step 1: Acrylic Sheet Placement

Place the acrylic sheet in the designated area, and ensure that the sheet lies flat with the protective film on. Close the machine lid.

Step 2: Importing Design

This step requires you to use our software xTool Creative Space program. Upload your design file into the software.

Step 3: Adjustment of Cutting Settings

Cutting settings can be either selected from the preset "Material EasySet Library" or be customized manually as per your own need. 

Step 4: Cutting

Initiate the cutting process on the software and press the button on xTool P2 or S1. The laser will perform the cut according to your design.

Step 5: Finishing Touches

When the cutting is over, remove the acrylic and peel off the protective film.

Conclusion

Acrylic is a welcomed material for both DIYers and businesses to create varieties of projects for decoration or fashion. You can simply cut acrylic by hand, or you can resort to machines for higher cutting efficiency. To achieve the best effect, the laser cutting machine stands out and can help you handle acrylic cutting tasks with ease and fun.

Don't hesitate, cutting acrylic is not hard. Choose the tool you prefer and immerse in the world of creation now!