How to Cut Plexiglass with a Jigsaw

If you’re wondering how to cut plexiglass, a jigsaw is the perfect tool to do so.

Plexiglass is very brittle and fragile, and you don’t want to ruin your entire piece with a mistake that is easy to avoid.

Here, I’ll explain how to safely and precisely cut plexiglass with a jigsaw. I’ll also share how to ensure you don’t break or chip your plexiglass in the process.

What is Plexiglass

Plexiglass is a transparent plastic that goes by the title of “acrylic glass,” but the brand names Plexiglas, Acrylite, Lucie, and Perspex all indicate the same material. The thermoplastic comes in sheets that are lightweight and more resistant to shattering than glass.

Despite its durability, plexiglass is more prone to scratching than regular glass, so manufacturers often add scratch-resistant layers on top of the plexiglass. A conventional method of cutting this material is via laser, which achieves a clean cut.

​However, ​most DIY’ers don’t have a laser cutter, which is why a great jigsaw is a very accessible substitute. The jigsaw will work great, provided you follow these instructions so you don’t break the plexiglass. 

​Ways to Cut Plexiglass

• Use a jigsaw when you’re making curved cuts
• Use a circular saw for quick cuts that don’t have to precise
• Use a band saw if you have particularly brittle plexiglass
• ​Use a table saw ​when you’re making long straight cuts
• Use a laser cutting device if you’re fancy and own one

Although plexiglass is durable, it will break when stress is applied. Fortunately, it won’t shatter the same way glass does. Instead, it will break apart into large pieces without sharp edges.

A jigsaw is particularly good choice because of it’s ability to cut both straight and curved lines, while also allowing you to work across large plexiglass surfaces.

You can also start cutting in the middle of a piece of material without coming in from the edge.  This is done by drilling a hole in the plexiglass, then placing the jigsaw blade in the hole.

Jigsaws’ ability to cut straight, at angles, and in a circular (or another shape) motion makes them versatile tools for cutting plexiglass (along with a lot of your other woodworking needs).

​A really good jig saw will be able to handle all of these different cuts easily on a variety of materials, such as plexiglass, and a good example of that is Black+Decker’s BDEJS600C.

How to Cut Plexiglass with a Jigsaw

Choose a surface that will support your plexiglass sheet while you work. Dropping the material with a jigsaw in your hand not only ruins your project, but it’s dangerous too. Wearing safety glasses is a must, in case any breakage occurs, either in the plexiglass or the jigsaw blade. Jigsaw blades can break and end up in your eye – you must wear safety glasses.

1. Preparing the Plexiglass

One way to prevent your plexiglass from chipping as you cut is to apply masking tape on both sides of the cut before starting. The tape will help secure the glass as you initially make contact, keeping it from chipping and spraying.

Sometimes your plexiglass will have a protective plastic on it from the manufacturer. If this is the case, leave it on instead of applying masking tape. You can cut through the plastic and then remove it when you are done cutting.

Also, if the type of cut you are doing allows for it, try clamping the plexiglass down to a surface. Once you get into the cutting portion, it can be hard to hold the plexi in place at times.

2. Chose the Right Jigsaw Blade

Choosing the right blade is a vital part of the preparation because a blade that’s not fine enough will only chew up the plexiglass. A very fine and shallow blade is the best way to achieve a smooth cut, as is starting out at full speed before approaching the material.

A good choice for cutting plexiglass with a jigsaw is a 10 TPI (teeth per inch) bi-metal jigsaw blade. Another recommended choice is a really sharp hollow ground wood blade. Avoid very fine metal blades, as they can clog while cutting, melting the plastic in the plexi.

Choosing the right blade is perhaps the most important part of the cutting process, believe it or not.

3. Preparing to Cut

Cutting plexiglass with a jigsaw demands a fine balance of speed and control. Go too fast or too slow and the plastic will break or crack.

Do not start with the jigsaw blade in contact with the plexiglass – it can result in burrs, melting, or breakage.

Instead, allow the jigsaw to reach full speed before initiating the cut. This avoids issues like jamming but may affect accuracy, which highlights the importance of practice.

Plexiglass is prone to melting due to blade friction and heat.

Cutting too slowly intensifies the heat transfer, potentially causing warping and uneven cuts.

Conversely, cutting too fast risks fracturing the plexiglass. The ideal approach is a moderate, steady speed – not too fast, not too slow.

Pausing mid-cut is similarly problematic as it allows the surrounding plexiglass to heat up. A powerful cordless jigsaw can be useful in this situation, eliminating the need to stop due to a cord obstruction.

4. Preventing Plexiglass Breakage

​Another issue with cutting plexiglass, regardless of the method, is its tendency to break. Although it’s durable, plexiglass is somewhat brittle, and you run the risk of chipping or cracking the plexiglass.

Here are a few ways to avoid breakage:

​Use a Cooling Lubricant

​Applying a lubricant has two functions- it helps to cool the plexiglass and reduces friction.

Choose a non-flammable lubricant to apply to the plexiglass before cutting, and the sawing motion will proceed more smoothly.

Use Water

​Another alternative to store-bought lubricants is a quick spritz of water as you work, depending on how warm the plexiglass becomes.

You can use water to keep the blade of your jigsaw cool. The hotter the blade gets, the easier it is for the glass to warp or melt.

​Apply Masking Tape

​As I mentioned at the start, a layer or two of masking tape on the surface of the plexiglass can help prevent chipping by physically protecting the edges of your cut.

At the same time, the jigsaw will have no difficulty cutting through the tape at the same time it shears off the plexiglass.

Afterward, removing the masking tape is a simple and relatively clean process.

5. Cutting the Plexiglass with a Jigsaw

​Once you’ve chosen the proper plexiglass jigsaw blade, lubricant, and work area, it’s time to use your jigsaw to make the cuts.

Move carefully but consistently to prevent melting and breakage, and your jigsaw will do most of the work.

​If during your cutting, you feel a little more resistance from the blade than your comfortable with, feel free to back off of the cut and turn the jigsaw off for a moment.

You can start the saw back up from outside the cut when ready and re-enter.

​6. Cleaning Up the Edges

​When you’re done making your jigsaw cuts on plexiglass, you might be left with a few ragged corners or edges. Sharp cuts and curved edges can sometimes have this as a result.

If you want to clean up those edges and make them smooth, you can sand the areas with a ​fine grit of sandpaper.

If you really want a smooth edge, try using a router instead!

​When to Use Other Saws to Cut Plexiglass

​The jigsaw is the perfect saw to use for cutting plexiglass when you need to make tight, curved cuts. It is also really convenient, as you’re using a powerful, handheld saw. 

However, there are situations when it makes sense to use a different saw for cutting plexi:

​When to Use a Bandsaw to Cut Plexiglass

A bandsaw, with its long, continuous blade, is great for cutting plexiglass, reducing chipping compared to a jigsaw’s reciprocating blade.

However, bandsaws are less portable and versatile. Unlike jigsaws where you push the saw through the material, with bandsaws, you push the plexiglass through the cut.

While bandsaws provide stability, they limit intricate, tight curves achievable with a jigsaw.

When to Use a Table Saw to Cut Plexiglass

Table saws excel at making long, straight cuts in plexiglass, offering precision and efficiency.

However, they cannot make curved cuts and attempting so is dangerous and ineffective.

They are particularly useful for repeated identical cuts, speeding up the process once set up.

It’s crucial to use an acrylic blade specifically designed for cutting plexiglass if you’re using a table saw.

When to Use a Hacksaw to Cut Plexiglass

​Don’t use a hacksaw to cut plexiglass. It typically results in rough edges and potentially damaged material.

Unless expertly handled, a hacksaw’s performance is subpar compared to other saws.

Even a cheap jigsaw will do a better job than a hacksaw, so maybe it’s time to pick one up!

​Conclusion

​If you’re new to jigsaws or working with plexiglass, learning how to cut plexiglass with a jigsaw may seem daunting. But with these simple steps, it’s easier than ever to create a clean and intentional cut in your material of choice.