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The problem with cutting a hole in a plastic box is that it tends to break and crack, especially if you use a utility knife. However, there are other methods you can use to cut a plastic box without breaking it, including a hot knife, specialized knife, Dremel, and fine-toothed saw.
Each method has its own set of benefits and drawbacks, which I will outline. Here are four ways you can cut plastic without cracking or breaking it.
Contents
How to Cut a Plastic Box Without It Breaking
Lets say you have a Rubbermaid plastic tote, or perhaps a Sterilite plastic box, and you need to cut it without breaking it? Thin plastic isn’t inherently easy to cut. I’ve cracked quite a few plastic boxes in my day, thinking I could do it quickly and easily.
Learning how to cut through plastic isn’t hard though, and there are several ways to cut your plastic box without breaking it.
1. Use a Dremel Tool
You can use a Dremel tool to cut plastic. And, as long as you use it correctly, you won’t end up breaking the container or bin.
- Use a reinforced cutting disc
- Cut on a low speed
The Dremel can cut the plastic bin, but it will leave a slightly rough edge. You can clean up the edge with a file or sandpaper after you have made your cuts.
2. Use a Jigsaw
An electric jigsaw can be used to cut plastic cleanly and without breaking it. Jigsaws are great because they are highly versatile, provided you have the right blade for the material.
If precision isn’t vital, this is probably the quickest method. I love grabbing my jigsaw for this type of task.
- You will need to use a plastic-cutting blade, which is a blade with fine teeth.
- Beyond that, mark your cut line and move slowly.
- Use a drill or heated drill bit to make a pilot hole for the cutting blade.
This is a great method because it leaves a clean-cut and is quick and easy.
3. Use a Hand Saw
If you want to make a clean cut in your plastic box, you can use a hand saw with a fine blade. There are a few different kinds of hand saws that will work for this purpose.
The important thing is to use a fine-toothed blade. You can use a hacksaw, hand jigsaw, or fine-toothed saw.
Although it will take some work and muscle power, a hand saw is perhaps the best way to get a clean cut without breaking, snapping, or melting your plastic.
As with the electric jigsaw, you’ll need to create a pilot hole to feed the saw blade through to make your cut.
4. Use a Heated Nail or Drill Bit
If you decide to use a jigsaw or hacksaw to cut your plastic box, you can use a heated drill bit or nail to make a series of holes along your cut line. It’s an extra step, but it will make the box easier to cut and the cut line easier to follow.
- Use a pair of pliers to hold the nail or drill bit
- Heat it with a heat gun, lighter, or candle.
The metal does not need to be red hot, just hot enough to melt the plastic. A hot nail or drill bit cuts through plastic easily.
5. Use a Hot Knife
The hot knife method works by melting the plastic along the cut line. It is an easy way to make a clean cut without breaking or cracking the plastic box.
For this method, you need:
- soldering iron
- wet towel
- spare soldering tip
This is a good method because it’s quick and easy, but it can be messy because it involves melting the plastic.
- Take the extra soldering tip and flatten it with a hammer or mallet.
- Mark the line you want to cut and put the modified tip in your soldering iron and heat it up.
- Use the heated tip to cut the plastic box. The plastic will want to stick to the soldering tip as you cut.
- Wipe the tip on the damp towel to keep it clean.
If you don’t have a soldering iron, then you might want to consider the next option. Most beginner woodworkers have a jigsaw on hand.
Frequently Asked Questions
What Is the Best Tool to Cut Plastic Bin?
A rotary tool like a Dremel with a cutting wheel attachment is the best tool for cutting through plastic bins. A jigsaw or reciprocating saw can also be used, but may leave rough edges.
Can You Cut Plexiglass with a Box Cutter?
Yes, you can cut plexiglass with a box cutter, also known as a utility knife, but it may not give you the smoothest edge. Use a sharp blade and score the plexiglass several times along the same line to avoid cracking or breaking the material. After scoring, bend the plexiglass along the scored line to snap it along the cut. Smooth the cut by sanding the edge after cutting. Another option to cut plexiglass would be to use a fine-toothed saw, such as a hacksaw or a coping saw.
Can an Exacto Knife Cut Plastic?
Yes, an Exacto knife, also known as a hobby knife or a precision knife, can be used to cut plastic. Exacto knives have a sharp blade and are designed for cutting through a variety of materials, including plastic. Use a sharp blade and make slow, deliberate cuts to avoid cracking or breaking the material. Sand the edges when finished cutting.
Conclusion
Cutting plastic without breaking it is not necessarily easy. But, with these five different methods, you’ll have your choice of options, depending on what type of tools you have.
Each makes it possible to cut through plastic bins and containers without chipping or breaking them. If you do happen to make a mistake, use the best epoxy for plastic to fix it up.
