Handy and very durable, plexiglass comes in several colors, thicknesses, and sizes. Because it’s tougher than glass and doesn’t break into shards or slivers, its high level of resilience to cracking and shattering makes it somewhat tricky to cut. though it is definitely DIYable. With the right strategies and tools, learning how to cut plexiglass is a breeze.
How To Cut Plexiglass: The Three Best Methods
There are a lot of ways to cut plexiglass, but there are three methods that we consider the best and easiest to accomplish: utility knife, table saw or circular saw, or an oscillating multi-tool. Here are the ideal scenarios to use each.
Utility knife
A utility knife and a straight edge are the best tools to use to cut plexiglass under 3/16 inch thick. With repeated scoring and a quick snap, the cut is usually clean and quick. However, this option is only helpful with straight cuts.
Table saw or circular saw
A table saw or circular saw fitted with a plexiglass or carbide-tipped finish blade is a great tool for cutting plexiglass cleanly and accurately. But these tools are best reserved for plexiglass that is thicker than 3/16 inch, as thinner materials can be too flimsy to cut accurately.
Oscillating multi-tool
If you’ll be cutting curves or plunge cuts in plexiglass of any thickness, reach for an oscillating multi-tool. This tool is easy to control but can make accurate, delicate curves when fitted with a curved blade.
How To Cut Plexiglass with a Utility Knife
Remember that cutting plexiglass with a utility knife is best for a sheet 3/16-inch thick or thinner. This type of material is actually easier to cut with a utility knife than power tools, as it can be too flimsy and bounce too much for a table saw or circular saw.
You will need:
Steps:
- Do not remove the film on either side of the plexiglass. Measure and mark the plexiglass sheet to be cut to size using the dry-erase marker.
- Place the ruler or straight edge along the marked line.
- Lightly score the sheet along the straight edge with the utility knife. Rather than pressing hard, focus on cutting accurately.
- Make repeated scores along the line. Score the sheet around 10 times.
- Flip the sheet over and line the straight edge up with the cut. Lightly score the line again. Score two to three times.
- Place the scored line slightly over the edge of a table. Holding the sheet firmly to the tabletop, quickly and firmly press down on the edge of the plexiglass hanging over the edge of the table. This will snap the plexiglass at the score marks.
- Lightly sand the edge with 200-grit sandpaper.
How To Cut Plexiglass with a Table Saw or Circular Saw
When cutting stiffer, thicker sheets of plexiglass, a table saw, or circular saw can be the fastest method. It’s critical to use a carbide-tipped blade (in the fine, finish, or plywood variety). And don’t skip the painter’s tape as it can help reduce potential chipping.
You will need:
- Dry-erase marker
- Ruler
- Painter’s tape
- Hearing protection
- Eye protection
- Dust mask
- Clamp
- Table saw and push stick or circular saw and flat worktable
- 200-grit sandpaper
Steps:
- Do not remove the film on either side of the plexiglass.
- Measure and mark the cut line using the dry-erase marker.
- Place painter’s tape over the cut line on both sides of the plexiglass. Mark the cutline again on top of the painter’s tape.
- Put on your safety glasses, hearing protection, and dust mask.
- If you’re using a table saw:
- Place the plexiglass on the top of the table saw. Adjust the fence so the saw blade aligns with the cut line.
- Pull the plexiglass back slightly and start the saw. Allow the blade to get up to speed.
- Slowly and carefully push the plexiglass through the table saw blade. Make sure to keep hands, fingers, hair, and clothing away from the blade.
- Use a push stick to finish the cut.
- If you’re using a circular saw:
- Place the cutline slightly off the edge of a worktable. Clamp the plexiglass to the surface.
- Ensure that there isn’t anything underneath the plexiglass that you might cut.
- Align the circular saw blade to the cutline. Pull it back slightly and start the saw. Let the blade get up to speed.
- Carefully push the saw through the plexiglass, making sure to keep the front edge of the blade aligned with the cutline. Be sure to keep your hands, fingers, hair, and clothing away from the blade.
- Cut all the way across the line. Carefully support the plexiglass as you cut.
- Sand the cut edge with 200-grit sandpaper for a smooth finish.
How To Cut Plexiglass with an Oscillating Multi-Tool
If you need to make curved or plunge cuts in plexiglass, an oscillating multi-tool is the way to go. This tool moves its blade back and forth very quickly but in very short, controlled paths, allowing the user to safely and accurately cut the material. For curves, be sure to use a curved blade.
You will need:
- A dry-erase marker
- A shape to trace
- Clamp
- Work surface
- Hearing protection
- Eye protection
- Dust mask
- Oscillating multi-tool with a curved multi-material blade
- 200-grit sandpaper
Steps:
- Do not remove the protective film on either side of the plexiglass.
- Use the dry-erase marker and a shape to trace the curved pattern on the plexiglass.
- Clamp the plexiglass to the work surface to prevent it from bouncing while cutting.
- Put on your hearing protection, eye protection, and dust mask.
- Start the multi-tool and set it to mid-speed.
- Carefully start cutting along the curve with the blade. Lightly score across the shape first, creating a groove to follow.
- Once there is a sufficient groove to follow, move the blade slowly across the plexiglass, allowing it to cut down into the material. Continue along the shape, being careful to keep hands, fingers, hair, and clothing away from the blade.
- Lightly support any cut edges as you cut to prevent unnecessary cracking or misshaping.
- Lightly sand the edges with 200-grit sandpaper for a smooth finish.
Note: An oscillating multi-tool can also make straight cuts in plexiglass, though it’s not the fastest option compared to a circular saws or table saw. However, if a multi-tool is all you have, it can cut a wide variety of different shapes and patterns in plexiglass material.
Other Tools That Can Cut Plexiglass
While a utility knife, a table or circular saw, or an oscillating multi-tool are our favorite options for accuracy, ease, and control, there are numerous other ways to cut plexiglass:
- A jigsaw with a fine-toothed blade can cut straight or curved lines, though it can be frustrating to use when the plexiglass binds on the blade and bounces.
- Reciprocating saws can also cut plexiglass, as can a Japanese-style pull saw, handsaw, hack saw, coping saw, or other hand tools.
- Rotary tools such as those made by Dremel are also handy for cutting plexiglass.