How to Cut Plexiglas

Commonly used as an inexpensive, lightweight substitute for glass, this acrylic plastic requires patience when cutting because of its proclivity to chip and melt.

You will need

  • A tape measure or a ruler
  • A pencil
  • Safety goggles
  • Gloves
  • A scoring knife
  • A work table
  • A table
  • circular
  • or band saw
  • Clamps
  • Sandpaper
  • Special Plexiglas-cutting blades (optional)

Step 1 Measure the shape Measure your shape with a tape measure or ruler and mark it with a pencil. New Plexiglas sheets are typically covered with protective paper. Try to leave as much paper as possible on the Plexiglas to minimize scratching.

Step 2 Prepare to cut the Plexiglas Put on your safety goggles and gloves. Use the scoring knife to lightly score along your cutting lines.

Step 3 Score and break thin pieces Score the Plexiglas where you want it to break, and then line the sheet up along the edge of a table with the scored side facing up. Sharply bend the Plexiglas down and snap it along the scored line.

Step 4 Cut with a saw Use a table saw or band saw when cutting through Plexiglas that’s more than ¼-inch thick. Clamp down the Plexiglas to prevent slippage.

Step 5 Sand the edges Sand the edges of your Plexiglas when you’re finished cutting. Use fine grain sandpaper for a smooth finish.