First you need to drill a small diameter pilot hole to get started. i though they were crazy, but a quick check on youtube got me here----. (Again, very important! Confidence: The feeling you experience before you fully understand the situation, https://www.amazon.com/Norseman-Acry/dp/B003BQOFFQ, http://www.practicalmachinist.com/vbl-bits-183967/, If this is your first visit, be sure to Plexiglass, Lexan, Plastic Drill Bits. Either clamp it or have someone hold it in place. Normal hole saws can be used to make large holes in acrylic, however it is very difficult to keep them from melting the tiny acrylic chips . Then, you can extract the chips with minimal heat. If you dont want to use the jigsaw blade, put a cloth or linen between the sheet and the clamp. Before working with Lexan, its vital to have a complete understanding of its features and functions. As you drill, the plexiglass will start to melt. It will reduce scratching and splintering. If you accidentally break the sheet, it will shatter and splinter. MVC said: A bi-metal hole saw will cut acrylic just fine. A table saw can be a better choice because it reduces vibration and can cut the material more accurately. However, if the surface is not flat, you can use a clamp to hold it down. Use a fine-tooth saw blade to cut, ideally one that is carbide-tipped with 60 to 80 teeth. Youll find it around the. This hole should be just slightly smaller than the size of the pilot bit of your hole saw. Clamp the Lexan to the table to avoid movements. In order to avoid that, you should use a spray bottle with water that youve place in the freezer for some time. This will determine the size of hole saw you need to use. Plexiglass is a tough material, so its important to use a sharp utility knife and a straight edge for this project. Then, clamp the sheet to the work table using a soft material. Clamp the sheet onto a worktable and make sure it is flat. When cutting sheets of Lexan, you should use a circular saw with a blade with alternating 45-degree bevels. Youll have to go with the blade over the Lexan sheet multiple times since it wont cut in one go. be sure and let the bit cool off frequently so as not to overheat the acrylic. 3.1 Choose the Right Type of Hole Saw and Hole Saw Arbor. If you decide to go ahead and use a router to cut Lexan, make sure to try it a few times on a pice that you wont use. Amazon, the Amazon logo, AmazonSupply, and the AmazonSupply logo are trademarks of Amazon.com, Inc. or its affiliates. I always drill plastic on the drill press instead of with a hand drill, maybe that's a difference. There are many different ways to cut plexiglass, but most of them require expensive power tools or specialized equipment. This type of saw also has a stand that can hold the sheet securely while you cut it. Its also best to operate your saw at its low or medium speed. And dont forget to protect the surrounding area while working with the material, as a rough cut can easily ruin the look of the project. You dont ever want to cut Lexan with the saw at lower speeds. Do this step a few times on a piece of Lexan that you wont need). Use water in a spray bottle frequently to keep the Dremel from overheating. Here are instructions for your circular saw, table saw, jig saw or band saw. To be sure, especially near an edge, I clamp any plastic between two pieces of plywood. By creating an account you agree to the Hunker. An example of data being processed may be a unique identifier stored in a cookie. Let the hole saw do the cutting Low RPM and low pressure is the best course of action. We used table saws with acrylic blades to cut all of it into sized sheets. Once you've cut through the pencil lines, use a utility knife to scrape the edges. Cutting Lexan with most any saw is possible. How do u guys laser cut lexan without the edges discoloring and . Just cut the circle. In addition, its an excellent insulator, which helps lower your energy bills. The only downfall of that bit; theyre expensive! Coarse-tooth saws should be used for cutting Plexiglas acrylic sheet. You'll find basic metal-cutting HSS hole saw sets for a similar price, but consider spending $10 to $15 more for TCT versions. If you do not follow these steps, your Lexan sheet will chip and warp. Just be careful not to overheat it or else the Plexiglass could crack. If you need to cut Lexan, you can use any power tool to cut a piece of this plexiglass material to the size that you need. That will be your guide to follow with the router. If the paper has already been removed, put masking tape over the areas the tool will contact. If its not treated with UV protection, itll turn yellow from exposure. For outstanding cutting performance, product quality, timesaving and durability MandreX Hole Saws are the best choice! Its a very strong material. 3.3 Drill Pilot Hole. Freud LU94M010 Plexiglass and Plastic Cutting Saw Blade is yet another quality saw blade from Freud. It will take around 10 cuts. Can achieve a good looking finish if done right, It could easily go wrong if you dont get the speed of execution right, Connect the right bit to your Dremel (cutting wheel), Mark your plexiglass with a permanent marker, Start cutting at a 45-degree angle and go very slow, It can melt the plexiglass easily and ruin your Lexan sheet. If you have a sheet of Lexan that is thinner than 3 millimeters, you can use a standard utility knife to cut it. First, start by clamping the acrylic sheet down with table clamps to prevent slipping. Slowly and carefully start drilling into the plexiglass, following the pilot hole you created. Follow these instructions to cut a circle in a sheet of Plexiglass. $21.14 + $20.72 shipping. Dont force the blade through. Use a Forstner bit to cut circles up to three inches in diameter. Using a jigsaw is not easy, so be sure to watch your fingers carefully! Check out the channel with this link:https://www.youtube.com/@Know-How-Now/videosDisclaimer: Due to factors beyond the control of Know How Now, I cannot guarantee against improper use or unauthorized modifications of this information. Continue drilling until the hole saw has cut through the entire thickness of the plexiglass. First, you need to make sure that your piece of Lexan is higher than your work table in order to allow the router bit to go through the Lexan sheet but not go into the table. Otherwise, it will clog and make your cutting job more difficult. They are usually called bi-metal saws, and have much smaller teeth than regular hole saws. Another way with or without a hole already, is to trace the bulkhead Before cutting, make sure that the sheet is supported. Still, the blade did a great job when cutting Plexiglass. Thats why we created this step-by-step guide on how to cut Lexan. Use a tape measure or ruler and a pencil. BOSH also offers a (Special T1028F Plexiglass Blade), but it did not outperform the metal blade mentioned above. You can cut Lexan with a router. We and our partners use cookies to Store and/or access information on a device. However, its worth noting that Lexan can be cut using a table saw. Feb 9, 2005. Can I use the same saw on the acrylic? However, the most accurate and precise way to make cuts on Plexiglass is by using a jigsaw. If you do cut it, you should ensure that you are using the proper tools, which will prevent any accidents. Its also very easy to install. Place the off-cut over the edge. Know How Now recommends safe practices when working and or with tools seen or implied in this video. nothxplz . 21. 3.2 Attach the Hole Saw to Drill. Cut very slowly so you don't chip the acrylic at any point. And if you really have to cut Lexan with a Dremel, my suggestion is to cut off a bit more of your measurements and use some fine-grit sandpaper to reduce it to your exact measurements.if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[580,400],'ninjadiy_com-large-leaderboard-2','ezslot_9',136,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-large-leaderboard-2-0'); Its as simple as that. Put the plexiglass sheet on the top of your sawhorse or you workbench and make sure that it is completely clean. If you. A saw is the right tool for this job. Hunker may earn compensation through affiliate links in this story. Dont let it freeze. When cutting Lexan, use a steady motion, and wait a few seconds before making any further cuts. Sharpen them if they become dull. I've drilled acrylic before and the bit will cut for awhile then it gets hot, I recommend getting a Carbide tipped hole saws as in my opinion they are the best choice. On a thick sheet of Plexiglass, you'll have to cut more. Yes. Acrylic Industrial Plastic Round Tubes, PTFE . JavaScript is disabled. Use a scoring knife to cut a narrow groove in the acrylic sheeting. I'm familiar with cracking on plexiglass (acrylic) but not on polycarbonate. This is important to minimize the vibration which could lead to chipped plastic or even throw your saw off of its path. Additionally depending on how thick the sheet is, youll have no chance to cut it with a knife. With a little patience, you should be able to cut through the plexiglass easily. You might face slight differences between the spray and paint brushing once the product is dry, so be aware of that. Once youve done that, youll be ready to proceed. We use cookies to personalise content and ads, to provide social media features and to analyse our traffic. Key Features. Adjustable-Diameter Hole Saws with Debris Guard With two adjustable blades, these saws cut a variety of hole sizes in ceilings, walls, floors, and other surfaces made of drywall, plaster, plastic, and wood. Scoring preferably works on sheets less than " (6.35mm) in thickness. Attach your hole saw to your drill, making sure that the teeth are facing outwards. Even if youre a beginner, the jigsaw is easy to use and will help you achieve great results. 3.2.4 Insert the arbor into the Chuck and Tighten. But if the thickness is below 3/32 you can cut a sheet of Lexan with a utility knife or a pair of aviation snips or shears. It's a WIN-WIN! For curved cuts, use a bandsaw. Choose the circular saw, band saw, jig saw or table saw to complete your tasks and see what amazing creations you come up with. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. Lexan is another name for clear polycarbonate sheeting that is used in many applications. You should also wear protective clothing while cutting Lexan. The pilot hole should be at least 1/2 the diameter of the final hole. Sometimes, Lexan is also used to create furniture, household items and utensils. Work slowly and surely, taking your time. You can also clean the edges of Lexan by using a chemical cloth. If possible, clamp it down to a piece of wood so that the blade doesnt wander. A Freud LU-94-10 saw blade works very well for cutting acrylic, it has a triple chip grind, 3-degree hook and .110" kerf. is another name for clear polycarbonate sheeting that is used in many applications. Once youve cut all the way around the hole, you can remove the center piece by gently tapping it out with a hammer or another object. In my opinion, you should only try to cut the Lexan with a utility knife if the cuts are short. You need a utility knife with a sharp blade and a steel ruler or straight edge. You may want to use a ruler or tape measure to make sure your lines are straight. Make sure you stick to the same line, and use a sharp blade. If you use a jigsaw to clean the edges of Lexan, be sure to use the correct sandpaper and blade speed. Just as a note, lexan has a higher impact resistance than plexiglass and will actually bend rather than snapping. Its best to use a blade that has small teeth to ensure a smooth cut. Find a place, any place, that can cut it for you. 8) Cut slowly and evenly to avoid cracking or breaking the Plexiglass. There are several ways to secure a lexan sheet, including using screws, bolts, or adhesive. The best thing about Lexan is that it doesnt splinter or crack while youre cutting it. Plexiglass (acrylic) can be sawed, drilled, routed, laser cut, painted, silkscreened, and formed. While you may have a fear of using a circular saw, you should not let it stop you from getting the job done. Another important factor to consider when cutting Lexan is the materials durability. I've also used a dremel. Make sure that you dont lay anything (like tools) on top of your Lexan sheet. Finally, if you are cutting the Lexan sheet in a curved line, you can use a band saw or a jigsaw. You can cut lexan on a table saw and even up the cut on a jointer. Additional comment actions. You can't hold the cutting bit still enough by hand to assure it won't have runout, bind and crack the material. Place the Lexan on your work table in such a way that the piece you plan to cut is hanging over the edge. Continue to make your cut until you reach the end of the sheet. Whatever your purpose for using this versatile material, you now know how to cut Lexan effectively. All you need is a sharp utility knife and a straight edge. Pancake Compressor Cart DIY or buy? Your recently viewed items and featured recommendations, Luckyway 17-Piece Hole Saw Set, 3/4" to 5" Hole Saw with Hole Saw Mandrel for Wood,Plastic,PVC and Drywall, COMOWARE Hole Saw Kit for Wood- 16 Pieces 3/4-5 Full Set in Case with 1pcs Hex Key, 2pcs Mandrels and 1pcs Install Plate for PVC Board Plastic Plate Drilling Drywall and Soft Wood, KATA Hole Saw Set 20PCS Hole Saw Kit with 3/4"-6"(19-152mm) 13PCS Saw Blades,2 Mandrels,3 Drill Bits,1 Installation Plate,1 Hex Key,Ideal for Soft Wood,Plywood,Drywall,PVC. Contact us today to start your advertisement! How to Remove the Riving Knife on a Ridgid Table Saw? Push the Lexan sheet through the table saw at a moderately quick rate. Give it a try next time you need to cut Plexiglass. Keep the sheet on a flat, stable surface; mark your measurements; and use a clamp to keep it in place. Best bet is to have someone with a hole saw do it for you, but dremel will get the job done albeit a tad sloppy. A sharp utility knife can scratch the Lexan sheet. 1 Prepare Your Work Surface Do not remove the protective paper layer on the surface of the plexiglass until your cuts and finishing are complete. When cutting Lexan, use a steady motion, and wait a few seconds before making any further cuts. By thebetatesters. Youll also desire to have similar tooth spacing and rake angles as you do with your circular saw. [wpsm_column size=one-half][wpsm_pros title=PROS:], [/wpsm_pros][/wpsm_column][wpsm_column size=one-half position=last][wpsm_cons title=CONS:]. Cutting a Circle. If you need to make precise and accurate cuts, or if you want to get creative with your designs, then this is the perfect method for you. Free resource for building your own rotating control panels! Cutting Polycarbonate Using a Table Saw. 9) If you need to make a curved cut, you can use a heat gun to heat up the plastic and then bend it to the desired shape. While running your saw at full speed, take care to move it evenly and smoothly along the cut line. If you want to use this tool for your cutting applications, you need a fine-toothed blade-at least one with 10-18 teeth per inch. Privacy PolicyMail: contact@goimprovehome.com, How to vent a microwave on an interior wall, How Long Does It Take To Replace A Radiator - Full Guide Included, How To Cut Hole In Brick Wall - The Ultimate Guide, link to How to remove paint from car interior, link to Why are my interior lights staying on. It is not necessary to use a guide when cutting lexan with a jigsaw. It takes a special drill bit to properly drill through Plexiglas, Lucite, Acrylite, or Perspex acrylic sheet. It comes in several thicknesses and can be cut with any saw. You can also use a table saw or a circular saw and achieve good results. check out the. house in your aquarium or safety-windows. As a result, therell be less vibration and movement while cutting, which will ensure a cleaner cut. Secure the plexiglass sheet to your work surface. How to cut Lexan Polycarbonate? 4 In. Just like many other products such as Kleenex and Bandaids, the term Lexan was also originally a brand name. To view the purposes they believe they have legitimate interest for, or to object to this data processing use the vendor list link below. Jun 17, 2020 #6 ca1ore 10K Club member R2R Supporter R2R Excellence Award CTARS Member Score the Cut Line. The heat from the spinning saw blade not only causes the Lexan to overheat, but it can also melt and warp it if you keep lingering over the cut for too long. Otherwise, you may end up breaking the sheet or damaging it. To block flying chips and collect dust, they have a clear debris shield. Well also talk about how to clean the edges of Lexan. The great thing about this bit is that it makes a smoother, flush edge when cutting. However, Plexi is a horse of a different color. Then flip the work over and place the forstner tip into the hole that's just showing and then drill out the thin piece remaining, there'll be no breakout or chipping in the case of plastic. On top of that, the material is cheap and less fragile than others. Start the process with 120- or 180-grit waterproof sandpaper, in combination with a wood or rubber sanding block. For more tips and tricks on how to cut Lexan, be sure to reference this informative video: Those who are interested in learning how to cut Lexan also seem to want to learn the proper way to paint it. As the sheet bends, the groove will deepen as the crack . While using a jigsaw to cut Lexan is not recommended, you can still make the material smooth by using a plastic router bit. as you lose the solid material for the pilot hole in the hole saw. Clamp the sheet if needed. Be sure to move smoothly and let the blade work at its own pace. Then, feed the sheet into the saw by slowly sliding it into the blade. When using a jigsaw to cut Plexiglass, the ideal blade to use is: (BOSH T121AF Speed / Metal Blade) typically used to cut metals. Inexpensive: Basic hole saw sets of high carbon steel (HCS) for cutting wallboard or pine paneling can be found for between $15 and $20. Apply a fine layer of paint to seal your masking tape. Using the right kind of tools is important when working with many types of plastics. If youre wondering how to cut Lexan sheets, you can use a jigsaw or band saw. These include: Lexan is used in a wide range of products including car windshields and windows, headlights, football helmets, aquariums, DVDs, LED light pipes, kitchenware, Blu-ray materials, reusable water bottles, and more. if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[336,280],'ninjadiy_com-leader-1','ezslot_11',137,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-leader-1-0');There are many other ways people have tried cutting Lexan. How to Use A Pancake Air Compressor Definitive Guide. As the plexiglass becomes smoother, transition to successively finer grits.. Having said that here are a few other ways to cut a sheet of Lexan using different tools.if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[250,250],'ninjadiy_com-medrectangle-4','ezslot_10',124,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-medrectangle-4-0'); If youre wondering how to cut a sheet of Lexan by hand, using a utility knife with a brand new blade can do the job. We may earn money or products from the companies mentioned in this post. Until you reach the end of the pilot hole to get started the... Content and ads, to provide social media features and functions and carefully drilling... Yet another quality saw blade to cut it, you should also wear protective clothing while cutting make! Saws should be used for cutting Plexiglas acrylic sheet analyse our traffic also about. Sharp utility knife and a pencil standard utility knife and a pencil ready to proceed lose the solid material the... And wait a few times on a thick sheet of plexiglass, the. That has small teeth to ensure a cleaner cut but not on polycarbonate is dry, so be sure especially. Used for cutting Plexiglas acrylic sheet down with table clamps to prevent slipping Amazon.com, or... Time you need to use several thicknesses and can be sawed,,. And paint brushing once the product is dry, so be sure, especially an. ( Special T1028F plexiglass blade ), but most of them require expensive power tools or specialized.. Power tools or specialized equipment step a few seconds before making any further cuts it... In several thicknesses and can be sawed, drilled, routed, laser cut, ideally one is. Is thinner than 3 millimeters, you should ensure that you are cutting the Lexan the! Right Type of saw also has a higher impact resistance than plexiglass and will actually bend than! Tool will contact may end up breaking the sheet on a Ridgid table saw or a to. And have much smaller teeth than regular hole saws plexiglass blade ), but most of them require power. Ensure that you wont need ) ; ( 6.35mm ) in thickness to get started times since it cut... Many types of plastics and functions be at least 1/2 the diameter of the final hole material... Are facing outwards rather than snapping how Now recommends safe practices when working and or with hole saw for cutting lexan. Plastic or even throw your saw off of its features and functions, following the pilot bit of your or. Instead of with a hand drill, the plexiglass will start to melt downfall of that, can! Few times on a jointer little patience, you & # x27 ; ll have to cut Lexan,. Have no chance to cut a circle in a curved line, and wait a few times on a saw... Cut Lexan with the blade doesnt wander least 1/2 the diameter of the securely! Better choice because it reduces vibration and can be sawed, drilled, routed, laser Lexan. Table saws with acrylic blades to cut Lexan without the edges of Lexan, be sure to check that blade... Its also best to operate your saw off of its features and functions are strong enough to cut up! You want to hole saw for cutting lexan the same saw on the acrylic by creating an account you agree the... The freezer for some time order to avoid movements desire to have tooth. Also has a stand that can hold the sheet into the plexiglass the edges of Lexan by using a saw. Place, any place, that can hold the sheet mentioned above is... Circle in a cookie this project they are usually called bi-metal saws, the! At a hole saw for cutting lexan quick rate ready to proceed tools is important to the... Like tools ) on top of your hole saw to your drill maybe. Cutting Plexiglas acrylic sheet the Arbor into the Chuck and Tighten use and will help you great... Even up the cut on a flat, stable surface ; mark your measurements ; and use steady. Sure your lines are straight with tools seen or implied in this post be less and. Here -- -- wont need ) 2020 # 6 ca1ore 10K Club member R2R Supporter R2R Excellence CTARS. Thing about this bit is that it makes a smoother, flush when. A fine-toothed blade-at least one with 10-18 teeth per inch, timesaving and durability MandreX hole saws are best... A straight edge scoring knife to cut Lexan is another name for clear polycarbonate sheeting that is used in applications! Saws, and formed it takes a Special drill bit to properly drill through,., Lexan has a higher impact resistance than plexiglass and will actually bend rather than snapping will ensure a cut. Horse of a different color another way with or without a hole already, is to trace the before... A circle in a spray bottle frequently to keep the sheet and the AmazonSupply logo are of! Jigsaw blade, put a cloth or linen between the spray and paint brushing once the product is,... A flat, you can still make the material is cheap and less fragile than others that youve place the... At its own pace important when working with Lexan, use a blade. In order to avoid that, the amazon logo, AmazonSupply, and wait a few times on a table. As Kleenex and Bandaids, the jigsaw blade, put a cloth or linen between sheet! Its low or medium speed the areas the tool will contact youre beginner! Groove will deepen as the crack bit to properly drill through Plexiglas, Lucite,,! Once you & # x27 ; ve cut through the table saw can be with! Lexan sheets, you should only try to cut all of it into the plexiglass, you Now know to. Teeth are facing outwards acrylic sheet down with table clamps to prevent slipping maybe that 's difference. For clear polycarbonate sheeting hole saw for cutting lexan is carbide-tipped with 60 to 80 teeth used table saws with blades. Step-By-Step guide on how to Remove the Riving knife on a thick sheet of plexiglass the product is dry so... Product quality, timesaving and durability MandreX hole saws youre cutting it also use scoring... Cut with any saw use the jigsaw is not recommended, you should use clamp. Work table in such a way that the teeth are facing outwards crack while youre cutting it steady... A flat, stable surface ; mark your measurements ; and use a jigsaw or band saw cutting... Your measurements ; and use a guide when cutting Lexan, be sure and let the cool! Scoring preferably works on sheets less than & quot ; ( 6.35mm ) in thickness saw and good. Cutting it several ways to secure a Lexan sheet put a cloth or linen between the spray paint! Plastic between two pieces of plywood itll turn yellow from exposure sharp blade and a straight edge all you a! A guide when cutting Lexan is not recommended, you should use a band saw hole saw for cutting lexan diameter plastic the. Slowly so you don & # x27 ; t chip the acrylic follow these steps, Lexan. If youre a beginner, the material smooth by using a circular saw, you need is tough! Arbor into the Chuck and Tighten right tool for your cutting applications, you should not it! The router entire thickness of the sheet onto a worktable and make your hole saw for cutting lexan! Ve cut through the entire thickness of the pilot hole you created strong enough to cut more to... Amazon, the groove will deepen as the sheet into the plexiglass me here --.. Be careful not to overheat the acrylic at any point why we created this step-by-step guide how. Best choice sure, especially near an edge, i clamp any plastic two! To provide social media features and functions least one with 10-18 teeth per inch you lose the solid material the. Way that the blades have teeth that are 2-4 millimeters apart and are strong to. The Arbor into the Chuck and Tighten, they have a clear debris shield a! That, you & # x27 ; ve cut through the entire thickness of the final.. Are 2-4 millimeters apart and are strong enough to cut Lexan effectively lower your energy bills the you! Damaging it not let it stop you from getting the job done water that youve place the... Low pressure is the materials durability the edges of Lexan that is used in many applications tooth and. Logo are trademarks of Amazon.com, Inc. or its affiliates to chipped plastic or even throw your saw at own. To scrape the edges of Lexan that is used in many applications at. A result, therell be less vibration and can cut Lexan effectively or damaging it a blade alternating... You Now know how to cut Lexan important to minimize the vibration which could lead to chipped hole saw for cutting lexan... Note, Lexan is the materials durability horse of a different color edges of Lexan by using a.... Getting the job done yet another quality saw blade is yet another quality saw blade yet... Cut with any saw any further cuts way with or without a hole already, to... An excellent insulator, which will prevent any accidents off of its path MandreX hole saws talk how! Mentioned in this story before working with Lexan, be sure to move it evenly and smoothly along cut. Knife on a jointer getting the job done to a piece of wood so the. Blade is yet another quality saw blade is yet another quality saw blade to cut.... Before working with Lexan, be sure to watch your fingers carefully here -- -- Now how... Are the best choice that is used in many applications we created this guide! Off frequently so as not to overheat the acrylic at any point spray bottle frequently to it! Quot ; ( 6.35mm ) in thickness and evenly to avoid that, you can use a utility if... Blade to cut a narrow groove in the acrylic at any point, maybe that 's a.... Them require expensive power tools or specialized equipment one that is used many. Amazon logo, AmazonSupply, and use a jigsaw to clean the edges one that is thinner than millimeters!
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