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How to Cut Plexiglas. Commonly used as an inexpensive, lightweight substitute for glass,
this acrylic plastic requires patience when cutting because of its proclivity to chip
and melt. You will need A tape measure or a ruler A pencil Safety goggles Gloves A scoring
knife A work table A table, circular, or band saw Clamps Sandpaper and special plexiglas-cutting
blades (optional). Step 1. Measure your shape with a tape measure or ruler and mark it with
a pencil. New Plexiglas sheets are typically covered with protective paper. Try to leave
as much paper as possible on the Plexiglas to minimize scratching. Step 2. Put on your
safety goggles and gloves. Use the scoring knife to lightly score along your cutting
lines. Plexiglas shards can cut just like glass. Be sure to wear the proper shoes and
sweep up the work area when finished cutting. Step 3. Score the Plexiglas where you want
it to break, and then line the sheet up along the edge of a table with the scored side facing
up. Sharply bend the Plexiglas down and snap it along the scored line. Step 4. Use a table
saw or band saw when cutting through Plexiglas that’s more than ¼-inch thick. Clamp down
the Plexiglas to prevent slippage. Consider using special Plexiglas-cutting blades for
your table, circular, or band saw, available at your local hardware store. The blades have
many fine teeth and will minimize chipping, cracking, and melting. Step 5. Sand the edges
of your Plexiglas when you're finished cutting. Use fine grain sandpaper for a smooth finish.
Did you know World War II warplanes were outfitted with Plexiglas cockpits, windows, and gunner
turrets.