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Plexiglass is an affordable alternative to glass that you can use in many household projects. But using the right method to cut plexiglass is important because this material is prone to cracking and chipping during the cutting process.
In this article, I’ll discuss how to cut plexiglass with a table saw using the right technique to achieve the best cutting results.
Contents
What is Plexiglass?
Plexiglass, unlike the name implies, isn’t glass. It’s a clear and hard acrylic, thermoplastic petroleum-based material, that makes a cost-effective substitute for normal glass. It’s also shatter-resistant, lightweight, translucent, and sturdy material that’s commonly used in:
- Windows
- Screens
- Signs
- Lights
- Viewing panels of aquariums
There are different types of plexiglass sheets and the following information will allow you to understand whether you can use a table saw to cut the plexiglass sheets you have.
Extruded Acrylic Sheets
This type of plexiglass comes with a low melting point and it’s also not as durable and hard as other types. That’s why you should use hand tools to cut the extruded acrylic sheets.
Cast Acrylic Sheets
This is the type that most people think of when they hear the work plexiglass. These sheets are durable and hard and you can use a table saw to cut them easily.
Polycarbonate Sheets
These sheets are somewhere between the plexiglass types mentioned above. They come with a higher melting point than the extruded type but they’re not as hard as cast acrylic sheets and you can cut them using a table saw.
How To Cut Plexiglass with A Table Saw
Many people will use a circular saw to cut plexiglass, but a table saw is much more accurate. You can also make many repetitive cuts in a row using a table saw.
While it’s possible to use any type of table saw to cut plexiglass, I recommend you use a more powerful table saw that has at least a 2-horsepower motor and a 10-inch blade. You can use the following steps to cut plexiglass with a table saw.
Step 1: Ensure Safety
It’s critically important to ensure your safety while using a table saw. You should always wear safety goggles, and a dust respirator while using a table saw but it’s even more important if you’re planning to cut plexiglass. That’s because small plastic shards can shoot out during the cutting process which can hurt your face.
You should also avoid wearing jewelry and loose clothes and contain long hair before starting the cutting process.
Step 2: Choose Right Saw Blade
If you’re using a soft type of plexiglass, I recommend you use a blade that has fewer uniform teeth, like 50 to 60 TPI. If you use a blade with more teeth, it will create more friction that will melt softer acrylic sheets.
Keep in mind that it’s hard to prevent chipping and cracking while cutting plexiglass with less than 1/8-inch thickness. So, consider using a sheet that is at least 1/8-inch thick to cut with a table saw.
Additionally, you should use a blade with more teeth (60 to 80 TPI) for harder acrylic sheets as they can withstand more friction.
In either case, the best table saw blades are carbide-tipped teeth in order to minimize the risk of chipping and cracking.
Step 3: Take Measurements
Use a measuring tape to take measurements and mark the cut line on your plexiglass sheet with a marker. Consider the width of the table saw blade while taking measurements as it’ll decrease the height/width of your final results slightly.
Note: Do not remove the protective film that your plastic sheets have. It’ll keep it from getting scratched.
Step 4: Start Cutting
Place your sheet on the table saw with protective film side down and make sure the cut line is aligned with the blade. Turn the table saw on and start feeding your sheet through the blade slowly and steadily.
Do not apply force while feeding because it’ll increase the risk of chipping. Hold the sheet firmly during the entire cutting process to ensure a precise cut. It’s also possible to cut multiple sheets together by stacking them up and securing them using clamps.
Use a push block to push the material through the cut. This is safer than using your hand.
You should not feed the plexiglass sheet through the blade with more than three inches per second of feed rate if the thickness of your sheet is ¼ inches or more. If you have a thinner sheet, decrease your feed rate to one inch per second. The goal is to let the blade cut the sheet instead of rushing the process.
Step 5: Sand Edges
Once you have made the cut, you’ll need to sand the edges of your acrylic sheet. Having slightly rough or glazed-up edges is possible because of the nature of the material.
Start sanding the edges with a 120 to 180 grit sandpaper sheet with a sanding block gently. As the plexiglass becomes smoother, switch to sandpaper with an even finer grit. You can use a 600-grit sheet to achieve a very smooth finish.
Using a buffing pad attached to a cordless electric drill is also a great way to smooth the rough edges of plexiglass sheets. Not only does it produce great results but it also saves you a lot of time and effort.
Use the same steps to cut as many plexiglass sheets as you want.
Tips to Use a Table Saw to Cut Plexiglass
Keep the tips listed below in mind if you need to cut plexiglass with a table saw.
- Never use a dull blade to cut plexiglass sheets with a table saw as it will lead to chipping and even cracking in the worst cases.
- If you see that your sheet is melting, stop the table saw immediately and switch to a blade that has fewer teeth. But if you see that the edges of your sheet are getting chipped, consider using a blade with more teeth.
- If you have mistakenly removed the protective film from your plexiglass before cutting, apply masking tape on the cut line. It’ll decrease the chances of chipping and cracking.
- A table saw will only allow you to cut your sheets in a straight line. You can use other tools such as a jigsaw or Dremel to make irregular cuts in plexiglass.
- There are several alternatives to plexiglass available in the market. But you need to make sure that you buy the original product because of its superior quality.
FAQs
Can You Cut Plexiglass with a Utility Knife?
Yes, you can cut plexiglass with a utility knife if the thickness of your sheet is 1/8-inch or less. First, take the right measurements and mark your sheet using a marker. Then run the utility knife five to six times along the marked cut line with the help of a ruler to score the sheet. Make sure that you go a little deeper with every pass. After that, snap the plexiglass sheet to divide it into two pieces.
Can You Cut Plexiglass with a Circular Saw?
Yes, it’s possible to cut plexiglass with a circular saw. This method will generate pretty much the same results as a table saw. The only advantage of using a circular saw for this purpose is its portability. You’ll also need to follow the same rules that I have mentioned for a table saw like using a sharp blade with a large number of teeth and wearing safety gear.
What Is the Best Tool to Cut Plexiglass?
Using a table saw is the best way to cut thick sheets of plexiglass. But when it comes to thinner sheets, using a scroll saw will generate the best results. That’s because a scroll saw generates way less heat as compared to a table or circular saw which decreases the risks of melting during the cutting process.
Final Words
A table saw is a powerful tool that you can use to cut different materials including plexiglass but it can lead to chipping and cracking if you don’t follow the right process. I hope this guide will help you cut your plexiglass sheets with a table saw effectively to achieve the best results.
