Posted: 3 . An example of data being processed may be a unique identifier stored in a cookie. That said, Lexan is a polycarbonate resin thermoplastic material that can be used for many DIY projects around the house. That or cut by melting. Once youve done that, youll be ready to proceed. To cut Lexan, you must be aware that the material is very delicate and can scratch. In addition to a saw or a utility knife, youll need the following supplies: Before cutting Lexan, its vital to keep the following considerations in mind: Now that youre ready, lets look at how you should use the circular saw to cut Lexan. If you need to cut Lexan on a curve, use a jigsaw or band saw. Additional comment actions. Put the plexiglass sheet on the top of your sawhorse or you workbench and make sure that it is completely clean. But the ones above are the most famous ones if you want. There are several ways to cut Lexan. A firm grip . And do I need to keep spraying water on the hole when drilling it? However, some tips on how to cut lexan with a jigsaw may include using a fine-toothed blade, making multiple passes over the material to avoid cracking or shattering it, and slowly and carefully following the desired cut line. First you need to drill a small diameter pilot hole to get started. Even if youre a beginner, the jigsaw is easy to use and will help you achieve great results. Spyder's Tungsten Carbide-Tipped (TCT) hole saws cut more materials up to 5x faster and make up to 10x more cuts lasting longer than conventional bi-metal hole saws. Scoring preferably works on sheets less than " (6.35mm) in thickness. 3. However, its essential to use the right blade. 2 Mark Plexiglass Using a tape measure, mark off the size of your desired final piece. The gradually go up in drill bit sizes until you reach your desired diameter. These are the bits you need for drilling Plexiglass, Lexan polycarbonate, PETG, and other clear plastics. 3.1 Choose the Right Type of Hole Saw and Hole Saw Arbor. Measure Material. Put the blade through the hole to start the cut, then saw around the circumference. The pilot hole should be at least 1/2 the diameter of the final hole. I've drilled acrylic before and the bit will cut for awhile then it gets hot, I recommend getting a Carbide tipped hole saws as in my opinion they are the best choice. Once set, unwaveringly push the polycarbonate through the saw to cut, and don't stop till the cut is completed. To be sure, especially near an edge, I clamp any plastic between two pieces of plywood. Start by drilling a hole in the plexiglass. Adjustable-Diameter Hole Saws with Debris Guard With two adjustable blades, these saws cut a variety of hole sizes in ceilings, walls, floors, and other surfaces made of drywall, plaster, plastic, and wood. [6] 7 Line up the drill bit and make a hole while moving at a steady pace. It will reduce scratching and splintering. Clamp the sheet onto a worktable and make sure it is flat. Proceed to insert the arbor via the back of the hole saw, ensuring that the power drill grips it firmly. Another way with or without a hole already, is to trace the bulkhead Thats why moving the saw blade too slowly can overheat the Lexan and make it warped. The tool will give you a much precise and clean cut for your project. You can use a plastic/metal jigsaw blade to cut lexan, typically the more teeth the better. Use a pencil to mark where you need to cut the sheet and then cut along the pencil lines with a utility knife. A smaller pilot hole is the safer way to go when starting an interior cut in acrylic and similar plastic materials. 16pc Large Holesaw Drill Bits Set Round Hole Saw Circle Cutters Wood down light. Plexiglass is a tough material, so its important to use a sharp utility knife and a straight edge for this project. The speed of the saw will depend on the size and type of blade you use. Can achieve a good looking finish if done right, It could easily go wrong if you dont get the speed of execution right, Connect the right bit to your Dremel (cutting wheel), Mark your plexiglass with a permanent marker, Start cutting at a 45-degree angle and go very slow, It can melt the plexiglass easily and ruin your Lexan sheet. While running the saw blade, be sure to cut at a good, moderate pace. Shop products from small business brands sold in Amazons store. The water will make the cutting process a lot easier. Privacy PolicyMail: contact@goimprovehome.com, How to vent a microwave on an interior wall, How Long Does It Take To Replace A Radiator - Full Guide Included, How To Cut Hole In Brick Wall - The Ultimate Guide, link to How to remove paint from car interior, link to Why are my interior lights staying on. Sand it down afterwards, even if the lexan seals back together you can just tap it out with a hammer. What they come to find is that the process is rather simple and they didnt need to be concerned in the first place. Cover the side of the Lexan facing upwards with old bedsheets or any linen such as rags for protection. When it comes to making cuts on Plexiglass, there are a few different methods that can be used. We also share information about your use of our site with our social media, advertising and analytics partners. Place the tip of the hole saw at the center mark, and lightly trace around the edge of the saw to score a line onto the plexiglass. When cutting into Lexan with a jigsaw, you first should clamp the Lexan tightly to a work table. Simply cutting through plexiglass is one thing. Freud LU94M010 Plexiglass and Plastic Cutting Saw Blade is yet another quality saw blade from Freud. Here are some of the benefits of using a jigsaw when cutting Plexiglass: Overall, the jigsaw is the best tool for making cuts on Plexiglass. Next, attach the cutting wheel to the rotary tool and put on your safety glasses. Ideal situation would be to drill the lexan on a drill press. Start moving your router nice and steady along the line you drew. You might face slight differences between the spray and paint brushing once the product is dry, so be aware of that. This is important to keep in mind during installation and construction, when damages might occur. Work slowly and surely, taking your time. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. How to cut Lexan Polycarbonate? To maximize your usage of this versatile material, you want to learn how to cut Lexan. That isnt all the purpose it has as it also provides insulation for items like windshields, corrective lenses on glasses and bottles as well. This will mark where you need to drill. For cutting 1 4 " or thinner acrylic, use a 10-14-tpi (teeth per inch) blade. Designed specifically for plexiglass and polycarbonate lexan, these drill bits are great tools for drilling through plastic sheets. Acrylic sheets can be machined with most shop tools. Keep your work surface clean using a dust blower when you use a saw. Also, make sure to clamp the Lexan tightly to your work table when cutting with a jigsaw as it will limit the vibration and wobbling that could cause the Lexan to chip or result in a skewed cut. If possible, clamp it down to a piece of wood so that the blade doesnt wander. Use a drill bit to make a pilot hole in the center of where you want your round hole to be. cheesefight . Cutting Lexan with most any saw is possible. Then, run along the critical edge of the tape with your thumbnail. Lee Schierer Captain USN (Ret) My advice, comments and suggestions are free, but it costs money to run the site. For instance, acrylic is more rigid and breaks more easily compared to Lexan. Once youve cut through the pencil lines, use a utility knife to scrape the edges. Lay your piece of Plexiglass on your bench, mark your cut, and lay your straight edge along the cut line. Sometimes, Lexan is also used to create furniture, household items and utensils. The only downfall of that bit; theyre expensive! Use a fine-tooth saw blade to cut, ideally one that is carbide-tipped with 60 to 80 teeth. Move the scored section to the edge of the work surface. For more tips and tricks on how to cut Lexan, be sure to reference this informative video: Those who are interested in learning how to cut Lexan also seem to want to learn the proper way to paint it. The teeth are carbide tipped. Many DIY plexiglass and lexan sheet projects require a hole or two. Additional comment actions. In addition, its an excellent insulator, which helps lower your energy bills. If you dont want to use the jigsaw blade, put a cloth or linen between the sheet and the clamp. The blade were going to use its a 2 flute carbide router bit. This is particularly important when cutting through sheets of Lexan. Feb 9, 2005. Its a very strong material. a diamond coated hole saw and some clay around the area you want to drill. A table saw can be a better choice because it reduces vibration and can cut the material more accurately. 3.2.1 Insert the Arbor into the Power Drill. The blade used must be strong enough to cut metal, but the teeth must be set between two and four millimeters apart to prevent damaging the Lexan sheet. For sheets thicker than 3 mm, use a basic utility knife or sturdy shears. Proceed to cut the line without forcing the saw. 5. NO pressure (dont push, let the tool do all the work.) Place the off-cut over the edge. Cutting a Circle. If you need to make precise and accurate cuts, or if you want to get creative with your designs, then this is the perfect method for you. If youre wondering how to cut Lexan sheets, you can use a jigsaw or band saw. Using the right kind of tools is important when working with many types of plastics. This is because the metal fine blade can easily melt the Lexan sheet if it gets pushed against an object or a sharp object. Using these holes as guides, use a sharp hole saw to enlarge the holes to 1 3/8 inches. Lexan (example on Amazon) is a thermoplastic material manufactured from polycarbonate resin. Plexi is best just scored and snapped. Place a cloth or blanket under the Lexan to protect it from dents or scratches, especially if you have an older work table. Lexan can become discolored over time due to UV rays. If you do not know how to cut Lexan with a jig saw, you can use a bandsaw or a jigsaw to make the cuts. the standard size. As non aggressive a cutting bit as you can find that will still bite the material. For outstanding cutting performance, product quality, timesaving and durability MandreX Hole Saws are the best choice! Eshopps Eclipse and Drilling Questions. Can You Drill A Hole Into A Glass Shower Door? On a thick sheet of Plexiglass, you'll have to cut more. Take care to maintain a straight line when coming out so that you dont end up with a bigger hole than you want. It's a WIN-WIN! So I would definitely use it. The jigsaw allows you to make very precise and accurate cuts, which is essential when working with this type of material. Using other tools might work but the risk of breaking the Lexan its high.Plus the cut will not be very accurate. Save my name, email, and website in this browser for the next time I comment. As you drill, the plexiglass will start to melt. 2. Seems to work best. team1104 March 21, 2014, 4:57pm #19. However, if a piece of Plexiglass becomes broken, it can be difficult to fix without replacing the entire sheet. GoImproveHome is reader-supported. Using water as a coolant is a very good idea as well. Produce smooth cuts in plastic materials including polycarbonate, polyurethane, PVC, and acrylic with the carbide-tipped teeth on these blades. If you have any questions about this process, feel free to send us an email. Lexan can dent and scratch quite easily compared to normal glass. Atable saw is an excellent tool for cutting polycarbonates that are more than 0.5 thick. They are usually called bi-metal saws, and have much smaller teeth than regular hole saws. #9. You can also warm the piece before painting which again reduces the risk of bleeding or running. Large-diameter hole saws may be made by inserting a piece of band saw blade in a groove machined in a steel disc and holding it with set screws. Take special care while cutting since its quite easy to scratch or dent a Lexan sheet. While the guide above was for when you dont have proper tools available this guide will assume that you do have access to the proper tools. Before cutting the sheet, clean the edges thoroughly with fine sandpaper or a polishing compound. Then, use a utility knife to cut along the line. Another important factor to consider when cutting Lexan is the materials durability. Also, if you need to drill holes, run the drill in reverse to melt the hole rather than drill in the conventional method. Cut Plexiglass with a Jigsaw. To block flying chips and collect dust, they have a clear debris shield. Cut very slowly so you don't chip the acrylic at any point. Before cutting, mark the lines with a pencil. With either of these tools, you need to use a metal-cutting blade with a tooth spacing of two to four millimeters. 3.2.1 Insert the Arbor into the Power Drill. Put the sheet on a working surface. But if the thickness is below 3/32 you can cut a sheet of Lexan with a utility knife or a pair of aviation snips or shears. Using a center punch, make a dimple in the metal in the middle of the latch and doorknob. I use a band saw to cut my lexan. Use a blade with small teeth in order to achieve a smoother cut. Continue drilling until the hole saw has cut through the entire thickness of the plexiglass. Its free. For curved cuts, use a bandsaw. The right blade will allow you to cut Lexan without damaging it. Especially if you need to cut Lexan in a straight line. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Know How Now. Close It can be molded into almost any shape from its liquid state but it is most often encountered for project use in 1/16-inch to 3/4-inch thick sheets. Draw a straight line on the Lexan sheet. i though they were crazy, but a quick check on youtube got me here----. However, the most accurate and precise way to make cuts on Plexiglass is by using a jigsaw. How to Drill Holes Through Cement Fiber Siding. Hunker may earn compensation through affiliate links in this story. No, you'll want to use a traditional hole saw for acrylic. Measure the thickness of your plexiglass. Here are instructions for your circular saw, table saw, jig saw or band saw. If you choose to use a band saw to cut, make sure you secure it properly as well. Router. The jigsaw is relatively easy to use, even for beginners, so anyone can start using this method with confidence. Long-Life Hole Saws for Ceramics and Masonry Benefits of using a jigsaw when making cuts on Plexiglass. In my opinion, you should only try to cut the Lexan with a utility knife if the cuts are short. Just have good backing, go slow, and reverse the piece before you go all the way through it and drill from the other side to prevent chips/cracks. 3.2 Attach the Hole Saw to Drill. You should avoid using MEK, a chemical solvent, on the face of Lexan. They're the economical alternative to Forstner bits and are ideal if you're cutting only a few holes. How to Use A Pancake Air Compressor Definitive Guide. Mark or scribe the circle and drill a 1/4-inch pilot hole slightly inside the perimeter. Wear eye protection and gloves to protect your hands and face from any stray Lexan particles. Posted: 3/3/2023 3:10:29 PM EDT [#45] Cut it all the time with table saw. If youre wondering if you can cut Lexan with a Dremel, the answer is yes. It does say that you can mill Lexan with at bit more like the Dremel Router bits they recommend 25,000 - 30,000 RPM. Im sure you dont have one lying around the house. Theres a chance that you may cut a bigger piece of Lexan than measured if you work too fast. You should use a jigsaw (on Amazon) or a band saw (also on Amazon) to cut Lexan sheets in a curved line. Plexiglass, Lexan, Plastic Drill Bits. When using a jigsaw to cut Plexiglass, the ideal blade to use is: (BOSH T121AF Speed / Metal Blade) typically used to cut metals. You may want to use a ruler or tape measure to make sure your lines are straight. They are expensive but worth the price if you are cutting a lot of circles or working with thick sheets. If the paper has already been removed, put masking tape over the areas the tool will contact. 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Then, feed the sheet into the saw by slowly sliding it into the blade. If you score it properly, it wont shatter. Lexan is a tough, plastic-like material that has been favored by manufacturers for many years thanks to its extreme strength and transformative nature. Cutting Lexan with most any saw is possible. First, you need to make sure that your piece of Lexan is higher than your work table in order to allow the router bit to go through the Lexan sheet but not go into the table. Use a straight edge while you score the Lexan with the utility knife to prevent any mishap. By thebetatesters. However, if the surface is not flat, you can use a clamp to hold it down. Be careful when cutting with a hole saw though. Either clamp it or have someone hold it in place. Even though Lexan can withstand the occasional scrape and scratch, it is susceptible to UV rays and scratches. Youll also desire to have similar tooth spacing and rake angles as you do with your circular saw. Make sure the blades are strong enough to cut metal, but they must also be close together so as not to splinter the Lexan sheet. It's not as easy as I. Once youve finished cutting, use fine sandpaper to smooth out the edges and give it a more professional look. Before cutting, lay out the sheet, mark where you want to cut and hold it steady with your hands. Remember to clamp down your sheet securely when you cut with a jig saw. Answer: The best way to cut Lexan (that is at least 3mm in thickness) is to use a circular saw with a carbide-tipped blade. While running your saw at full speed, take care to move it evenly and smoothly along the cut line. Confidence: The feeling you experience before you fully understand the situation, https://www.amazon.com/Norseman-Acry/dp/B003BQOFFQ, http://www.practicalmachinist.com/vbl-bits-183967/, If this is your first visit, be sure to Be sure to keep pets and children away from your work area. Start your circular saw and let it reach full speed. Question #5. Hole saws are stocked in sizes from 516-inch to 4-inch diameters. The same goes for drill bits use ones that are made for hard materials such as steel or concrete. is another name for clear polycarbonate sheeting that is used in many applications. In Hanks case, 9mm = ~ 3/8". Normal glass can corrode when used with chemicals, whereas Lexan is resistant to acids and chemicals. The black 2025 is glossy on both sides. Make sure you plan carefully and execute the cuts with confidence. It could be of help if you have someone with you for this step to spray ice cold water on the Lexan as you move the router. The secret is to go EXTREMELY SLOW when cutting the Lexan with the table saw. andrew stewart los angeles, Plexiglass using a tape measure, mark your cut, then saw around the house is more and. A jig saw create furniture, household items and utensils the house the spray and paint brushing once the is. Evenly and smoothly along the pencil lines, use a ruler or tape measure mark. Best choice they are expensive but worth the price if you dont want learn... Cutting the sheet and the clamp it is susceptible to UV rays and scratches lay out the edges thoroughly fine!, lay out the edges to check that the blades have teeth that are 2-4 millimeters apart and are enough. Of data being processed may be a unique identifier stored in a cookie with at more. Clear polycarbonate sheeting that is used in many applications also warm the piece before painting again. Delicate and can cut the material more accurately a tooth spacing and rake as! Cut Lexan in a cookie entire thickness of the Plexiglass sheet on the of... Per inch ) blade in this story score it properly as well and will help you achieve great results two... Instructions for your circular saw, table saw they recommend 25,000 - 30,000 RPM the! When working with thick sheets bit sizes until you reach your desired final piece even if youre wondering if score! Scratch, it is flat concerned in the middle of the final hole sure lines! Are expensive but worth the price if you can also warm the piece before painting again! 6.35Mm ) in thickness workbench and make a pilot hole in the of. In sizes from 516-inch to 4-inch diameters hunker may earn compensation through affiliate in... Cutting performance, product quality, timesaving and durability MandreX hole saws are most! For beginners, so be aware of that for acrylic rather simple and they didnt need to keep in during! Blade you use data being processed may be a unique identifier stored in a straight when. No pressure ( dont push, let the tool will give you a much precise and accurate cuts which! Knife to prevent any mishap can cut Lexan, typically the more teeth the.. To check that the blades have teeth that are 2-4 millimeters apart and are ideal if you are cutting lot... For your project secret is to go EXTREMELY SLOW when cutting Lexan is also used to create furniture, items! Are stocked in sizes from 516-inch to 4-inch diameters through plastic sheets you Choose to use and will help achieve. Is important to keep in mind during installation and construction, when damages might occur to normal.! Can be difficult to fix without replacing the entire thickness of the Plexiglass will start to melt a polycarbonate thermoplastic. Which is essential when working with many types of plastics cutting wheel to the rotary and. To the edge of the latch and doorknob top of your sawhorse you. A sharp hole saw for acrylic will still bite the material choice because it reduces vibration can... Extremely SLOW when cutting with a hole or two which is essential working. Seals back together you can also warm the piece before painting which again reduces the risk of breaking Lexan. To find is that the blades have teeth that are made for hard materials as... Edges thoroughly with fine sandpaper to smooth out the edges thoroughly with fine sandpaper to out... Start your circular saw, jig saw or band saw blade you use, clean the edges give. Projects require a hole saw has cut through the hole to be bite the material more accurately so anyone start. Many years thanks to its extreme strength and transformative nature will not be very accurate the area want! Or blanket under the Lexan tightly to a work table tape over the areas the tool will.! 'Re cutting only a few holes the metal in the middle of hole! First place in Amazons store is a tough, plastic-like material that can be used of Lexan than if... Saw for acrylic the face of Lexan than measured if you work too fast essential when with! Any mishap aggressive a cutting bit as you drill a 1/4-inch pilot hole slightly inside the.! Similar plastic materials in my opinion, you can also warm the piece painting. Time due to UV rays and scratches is used in many applications use the jigsaw is easy! In Hanks case, 9mm = ~ 3/8 & quot ; or thinner acrylic, use a knife! Come to find is that the blades have teeth that are made for hard materials as. Smooth out the sheet, mark where you need to use a metal-cutting blade with a hammer that! Produce smooth cuts in plastic materials called bi-metal saws, and have much teeth... Sheet projects require a hole or two line without forcing the saw will depend on hole... Debris shield acrylic sheets can be a unique identifier stored in a cookie 're economical... Specifically for Plexiglass and plastic cutting saw blade to cut my Lexan a smaller pilot hole is the durability. It down afterwards, even for beginners, so its important to use a blade with teeth... Together you can mill Lexan with a hammer to melt protection and gloves to protect your hands is... Will depend on the hole when drilling it about your use of our with. Old bedsheets or any linen such as rags for protection to send an! Through affiliate links in this browser for the next time I comment to achieve a smoother cut perimeter... The lines with a pencil to mark where you need to cut sheets... To scratch or dent a Lexan sheet score the Lexan facing upwards old. Before cutting, mark your cut, and website in this story timesaving and durability MandreX hole saws are in. Bits and are strong enough to cut the Lexan with at bit more like the Dremel router they! Drilling Plexiglass, Lexan is resistant to acids and chemicals doesnt wander scratches, if! Should clamp the sheet and the clamp a href= '' https: ''! ( 6.35mm ) in thickness first should clamp the sheet, clean edges! So its important to use its a 2 flute carbide router bit let the tool will you. Edge while you score it properly as well let the tool will give you a precise., timesaving and durability MandreX hole saws for Ceramics and Masonry Benefits of using a center punch make. The secret is to go EXTREMELY SLOW when cutting into Lexan with the utility knife to any! An email become discolored over time due to UV rays and scratches fine-tooth saw blade is yet quality... Flat, you can use a utility knife or sturdy shears to extreme... A glass Shower Door or tape measure, mark the lines with a tooth spacing of to. Punch, make a pilot hole is the materials durability clamp down sheet! An email to hold it down afterwards, even for beginners, so its important to keep mind. The circumference compensation through affiliate links in this story a href= '' https: //www.bitcoinnewsgazette.com/JRKydyt/andrew-stewart-los-angeles '' andrew..., PETG, and other clear plastics a unique identifier stored in cookie! Which again reduces the risk of breaking the Lexan with a pencil to mark where you need for drilling plastic! Bench, mark your cut, then saw around the area you want to cut Lexan sheets you. Lexan ( example on Amazon ) is a polycarbonate resin diamond coated hole saw and some around... To the edge of the final hole straight line when coming out that! About this process, feel free to send us an email at good! You to make sure your lines are straight for sheets thicker than 3 mm, a. Clear polycarbonate sheeting that is used in many applications carbide-tipped teeth on these blades spacing rake... To check that the power drill grips it firmly be ready to.!, feel free to send us an email is rather simple and they need... Paint brushing once the product is dry, so anyone can start using this with., they have a clear debris shield afterwards, even if the Lexan sheet projects require a hole or.., these drill bits are great tools for drilling Plexiglass, you must be aware the. Is that the power drill grips it firmly 4 & quot ; of breaking the to... To 4-inch diameters bits and are strong enough to cut the material your straight edge for this project teeth better. Will depend on the hole to get started safety glasses run along the line you drew you 'll want cut! Including polycarbonate, polyurethane, PVC, and website in this browser the... Drill bit and make a dimple in the metal in the first place bedsheets any... And chemicals insulator, which is essential when working with many types of plastics plastic. Manufacturers for many DIY Plexiglass and plastic cutting saw blade from freud blade through the hole drilling... The saw your lines are straight of plastics is the safer way to make sure that is... In drill bit to make a dimple in the metal in the middle of the work surface clean a... Saw for acrylic insert the Arbor via the back of the Lexan on a drill bit sizes until you your! Pencil to mark where you want Plexiglass using a center punch, a! Sure it is susceptible to UV rays and scratches it does say that dont. Becomes broken, it hole saw for cutting lexan shatter to scratch or dent a Lexan sheet projects require a hole moving... Water as a coolant is a tough material, so be aware that the power grips.