How to Safely and Cleanly Cut Plexiglass: A DIY Guide

Plexiglass, or acrylic, is a strong and flexible material great for DIY projects like furniture, windows, and picture frames. It's lightweight and shatter-resistant, but cutting it can be challenging if you don't know the right techniques. This guide will show you the tools and methods to cut plexiglass safely and cleanly, avoiding cracks or chips. Whether you're using thin or thick sheets, you'll find the information you need to complete your project with confidence.

What You’ll Need

Before you start cutting plexiglass, gather the right tools and protective gear. The tools you use will depend on the thickness of the plexiglass and the type of cut you need to make. 

For Thin Plexiglass (Up to 3mm Thick):

• Utility knife or plexiglass scoring tool

• Straightedge or ruler

• Clamps (optional) 

For Thick Plexiglass (More than 3mm Thick):

• Circular saw or jigsaw with a finetooth blade designed for plastics (carbidetipped or acrylic blade)

• Table saw (optional for large, straight cuts)

• Band saw (optional for curved cuts)

• Masking tape

• Sandpaper (various grits) or a file for smoothing edges

Safety Gear:

• Safety glasses or goggles (to protect your eyes from flying shards)

• Gloves (optional but recommended to protect your hands)

• Dust mask (especially if you’re using power tools) 

Step by Step Guide to Cutting Plexiglass 

1. Measure and Mark the Cut Line

The first step to any successful cut is accurate measurements. Use a tape measure or ruler to mark the cut line on the protective film of the plexiglass. If the film has been removed, apply masking tape along the cut line to prevent cracking or chipping during cutting. 

Mark with a straightedge: Use a straightedge or ruler to draw a clear line across the plexiglass where you’ll make your cut.

Doublecheck measurements: Always measure twice to avoid costly mistakes, as cutting the wrong size can lead to wasted material. 

2. Choose the Right Cutting Method Based on Thickness 

Cutting Thin Plexiglass (Up to 3mm)

Thin plexiglass can be cut easily with a scoring tool or a utility knife. 

Scoring Method:

1. Place the plexiglass sheet on a flat surface.

2. Position a straightedge along the cut line.

3. Using a scoring tool or a utility knife, score the plexiglass along the marked line. Apply firm, even pressure as you run the blade down the line. Repeat this motion 510 times to deepen the score.

4. Flip the plexiglass over and score the same line on the opposite side.

5. Once the score is deep enough, position the plexiglass along the edge of your workbench, with the score line aligned with the edge.

6. Apply downward pressure to snap the plexiglass along the scored line. 

This method is best for straight cuts on thinner sheets and is the simplest way to achieve clean cuts.

Cutting Thick Plexiglass (More than 3mm)

For thicker plexiglass, using power tools like a circular saw, jigsaw, or table saw will provide cleaner, more precise cuts.

Circular Saw Method:

1. Attach a finetooth carbidetipped blade to your circular saw. Blades with 80 teeth or more per inch are ideal for cutting plastics, as they minimize the risk of chipping or cracking.

2. Place the plexiglass on a flat work surface, securing it with clamps to prevent movement.

3. Apply masking tape along the cut line to further reduce the risk of cracking.

4. Slowly and steadily guide the circular saw through the plexiglass, keeping your hands clear of the blade. Allow the saw to do the work—don’t force it through, as this can cause the material to crack. 

Jigsaw Method (For Curved Cuts):

1. Use a jigsaw with a finetooth blade designed for cutting plastics.

2. Place the plexiglass securely on your workbench, clamping it down to prevent movement.

3. Apply masking tape along the cut line.

4. Slowly guide the jigsaw along the line, making sure to keep the blade moving steadily to avoid overheating or melting the acrylic. 

Power tools provide the best results for thicker plexiglass, but they require extra care to avoid chipping. Make sure your blade is sharp and designed specifically for cutting plastics to ensure clean edges.

3. Smooth the Edges

After cutting the plexiglass, the edges may feel rough or sharp. Smoothing them is essential for both safety and aesthetics. 

Sandpaper Method:

1. Start with mediumgrit sandpaper (around 120 grit) to smooth the roughest areas.

2. Move to a finer grit (320600 grit) for a polished finish.

3. If you have a larger piece, you can also use a file or rotary tool with a sanding bit to smooth the edges faster. 

For Extra Smooth Edges: After sanding, you can flamepolish the edges with a propane torch. This method requires experience, as applying too much heat can warp or damage the acrylic. Gently move the torch along the edge of the plexiglass to create a smooth, glossy finish. Practice on scrap pieces before attempting this on your final project. 

4. Safety Tips for Cutting Plexiglass

Cutting plexiglass can be hazardous if you’re not careful. Follow these safety guidelines to prevent injury:

• Wear eye protection: Flying shards of plexiglass can cause eye injuries, especially when using power tools. Always wear safety glasses or goggles.

• Cut in a wellventilated area: When cutting with power tools, acrylic dust can become airborne. Work in a wellventilated space, and consider wearing a dust mask to protect your lungs.

• Secure the material: Always clamp your plexiglass sheet to a stable workbench to prevent it from shifting during cutting.

• Use slow, steady motions: Rushing through a cut can cause the plexiglass to crack or chip. Take your time and allow the blade to do the work. 

Common Mistakes to Avoid

• Using the wrong blade: Don’t use wood or metal blades, as they will likely cause chipping and cracking. Always use a blade designed for cutting plastic.

• Forcing the cut: Forcing the blade through the plexiglass increases the risk of cracks. Let the tool and blade do the work.

• Skipping edge finishing: Rough or jagged edges are unsafe and look unprofessional. Always sand or smooth the edges after cutting. 

Conclusion 

Cutting plexiglass can be easy. With the right tools, methods, and safety steps, you can make clean cuts at home. Whether using thin sheets that you can score and snap or thicker pieces needing power tools, following these steps will help you cut safely and smoothly. By taking some time to prepare and cut carefully, you can get great results for your DIY projects.