Lexan cuts really nice, just make sure you keep the cutter moving, if you sit in one place too long you will still melt. However, you should apply a moderate amount of pressure. When you finish cutting, you can use medium grit to sand and make the edges of the cut pieces to become cleaner and smoother. We may earn money or products from the companies mentioned in this post. Step 1: First of all, you have to mount the table saw on the working table. You can cut Lexan with this tool using the similar steps that you would take when you cut with a circular saw. Here on, mark the cut line of the sheet by scoring the plastic with the help of a knife. Cutting plexiglass requires patience. That’s why we created this step-by-step guide on how to cut Lexan. Turn on the jig saw and guide it toward the mark that you have drawn on the sheet. Center this over the cut line of your windshield. Both materials cut well with a band saw or table saw using a high speed with small teeth. Learning how to cut acrylic sheet can lead to near-limitless application possibilities. You can also easily cut it to shape with the right tools, the proper precautions, and correct measurements. One trick to help prevent splintering is to stick painter's tape over the cut line. If you push it through too slowly, the blade could overheat and melt your plastic material. This reduces the risk of bleeding or running. This tool is also suitable for cutting other unique and original pattern. For any piece of Lexan which is more than 0.125 inches, you can use a circular saw. As you can see, it is quite easy for you to handle and cut a piece of Lexan. They should also have alternating 45-degree bevels in order to effectively reduce unnecessary chipping. Thin sheets can be scored and snapped with a utility knife or scoring tool. Lexan is a form of Plexiglas that is often used for windows in place of glass. A variety of cutting tools can be used depending on the polycarbonate’s thickness, hardness and purpose. Thickness of Lexan: In case a sheet of Lexan is thin and fragile, you should use a utility knife. Lexan is a strong, reliable alternative to glass. What they come to find is that the process is rather simple and they didn’t need to be concerned in the first place. Install a metal-cutting blade into the saw, with at least 10 teeth per inch of blade. Lexan is also known as Polycarbonate. Lexan is used for windshields on motorcycles, boats and cars. Check that you only a sharp blade. How to cut a polycarbonate Lexan sheet. You can get a very clean edge on acrylic by lasercutting it. Cutting Lexan with most any saw is possible. Also check if the sheet of Lexan can stay firmly and stably on the working station. You’ll achieve very good results if you use a tool such as a circular saw or table saw as well. You can cut with tin snips , smooth with a plane and sand round corners. If you’re thinking to yourself “it sounds like I shouldn’t cut too fast, and I shouldn’t cut too slow”… well, thats exactly right. This lightweight, plastic or polycarbonate resin has high levels of optical clarity and durability. How to Cut Lexan Sheets in a Curve. Lexan is a common material used in many home or construction projects. Heat up your paint first. For thicker Lexan, you can use a hand shears. If you found something of value here please give a little something back by becoming a contributor! Dave Lehnert. You can also use duct tape and place it on the sheet as an outline for your intended cut. When cutting into Lexan with a jigsaw, you first should clamp the Lexan tightly to a work table. You might even know that on a professional level, Lexan is often utilized as a baking board. Score your cut line on the material with a knife. However, it can scratch and dent quite easily. Continue to make your cut until you reach the end of the sheet. In general, sharp tooling with fine cutting teeth should be used to minimize vibration and clatter Sheets should be properly supported along the trim line before cutting. The technique of cutting Lexan is a lot similar to cutting cement board. Dremel recommends that you start at a 45-degree angle when cutting into a piece of material. It's brittle, and not supper strong, so it's easy to break off corners or small features. Adjust the saw speed so the blade is moving at approximately 12,000 strokes per minute. Thicker sheet material will have to be cut by means of a mechanical saw. Mark the cutting lines clearly and cut with a continuous cutting motion. In this case, right in the middle between fast and slow is perfect. To keep the saw from veering left or right on straight cuts, use a clamp-on guide. Take your plastic and lay it out on a table or saw station. Sand down the edges with medium-grade sandpaper for a smooth and even edge. This tool will take much effort and time for you to cut through the sheet of Lexan. I have a large piece (30x45) that I need to cut down to 13x22 and I'd rather not buy a special blade just for this one cut. Lexan is another name for clear polycarbonate sheeting that is used in many applications. The most difficult thing here maybe is about how to choose the right tool for the project. Lay your Lexan sheet flat on your workbench. Do you need one? You should always protect the Lexan with a cloth, clamp it in place, and use the right circular saw blade. Whatever your purpose for using this versatile material, you now know how to cut Lexan effectively. You don’t ever want to cut Lexan with the saw at lower speeds. Please Contribute . Note: Make sure when you use duct tape to fix the sheet of Lexan on the working surface, you don’t stretch the sheet too much. Lay your Lexan sheet flat on your workbench. Method 1 of 3: Scoring and Snapping Thin Plexiglass. Make sure you use a straightedge to effectively guide your knife. Step 1: Lay the sheet of Lexan on a clean working surface. @https://twitter.com/michaelbaker018. You should only work in a well ventilated area and avoid breathing in the fumes that are coming out of the saw blade. Acrylic is easy to work with but it’s also easy to mess up if you rush the process. If you have a jigsaw, you can cut Plexiglas. Today, we will be featuring a step by step guide on how to cut Lexan. Be aware that this area will be matte now, but that shouldn’t matter much if you are painting it. Cutting a Lexan windshield is simple, if you know a few basic tips. Make sure that the blade that you use is the sharpest. ToolsCritic.com is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to amazon.com. For other tools, you don’t have to press the blade too hard into the sheet of Lexan. Step 3 Turn the tool on to 6 or 8 and begin the cut. Lexan is a form of Plexiglas that is often used for windows in place of glass. You can cut lexan on a table saw and even up the cut on a jointer. Working naturally lowers your risk of having large chunks gouged from the Lexan material. Pattern: For curved cuts on a piece of Lexan, you can use a jigsaw. When the sheet makes contact with the blade, follow a slow and steady space. Plexiglas and Lexan are different materials: acrylic and polycarbonate, respectively. This type of material is lightweight and durable as it is resistant against heat and electricity. Step 2: Use the ruler and pencil to mark the points or lines that you are going to cut. Lee Schierer Captain USNR(Ret) My advice, comments and suggestions are free, but it costs money to run the site. Thanks to the nature of the plastic, it is quite easy to cut Lexan with various types of tools. That is the reason why this material is very popular among DIY hobbyists. Circular Saws: Use a fine-tooth, hollow ground panel blade with 10-12 teeth per inch. A few ways to cut different thickness sheets. I got a piece of lexan to try to protect my scope better (I am currently using 3 layers of packing tape, a suggestion by the owner of the field), and I dont know how to cut it. If you choose to use a band saw to cut, make sure you secure it properly as well. Therein lies the finesse of cutting plexiglass, especially curved cuts with a jigsaw. Besides the body-post holes, nitro rigs usually receive a few more whacks of the knife than their electric siblings, so before you paint the body, mark where you’ll need cutouts for glow-plug access, exhaust clearance, engine cooling and fuel-lid access. Best Battery Chainsaw In 2021 – Top Reviews & Comparison, How to Fill a Raised Garden Bed for Cheap Cost, Best Contractor Table Saw 2021 – Reviews & Comparison. Thicker sheets will need to be cut with either a circular saw for straight lines or a jigsaw to cut shapes out of the sheet. When cutting into Lexan with a jigsaw, you first should clamp the Lexan tightly to a work table. If you want to cut curves in the Lexan, use a jig saw or band saw. This tip will help you easily cut plexiglass with no chips or breaks. For smoother cuts, instead of making two spears close completely, you should stop when they are just about to close. Here are 3 things that you need to consider when you choose the right tool- the softness of a piece of Lexan, its thickness and the pattern which you want to cut the piece of Lexan into. Make sure you follow a slow and steady space so that you wouldn’t cut out of the intended line. In case you use a blunt blade, not only will it take a longer time for you to cut, it also cause potential damages to yourself. Place the off-cut over the edge. In case of a sheet of Lexan which is more than 0.5 inches, you should use a table saw to cut the Lexan. Especially if you need to cut Lexan in a straight line. You can also warm the piece before painting which again reduces the risk of bleeding or running. Sheet of 0.093" GE Lexan. 01-17-2018, 6:04 PM #7. Lexan is also known as Polycarbonate. Most importantly you need to think about the right tool for the project. Other things that you should prepare before cutting Lexan are pencil, ruler, duct tape and C-clamp. If this is the case, why not provide the highest quality polymers and plastics? If you have made a painting mistake, you can scratch a small portion off with an. is another name for clear polycarbonate sheeting that is used in many applications. If the cut needs to be straight, use a straightedge as a guide, clamping the straight edge to the plexiglass so it does not move. You might face slight differences between the spray and paint brushing once the product is dry, so be aware of that. Wood Deformation And How To Unwarp Wood Effectively, How To Sharpen Machete For Better Woodworking, The Important Worm Drive Saw Features You Should Know, Best Worm Drive Saw You Should Get In 2021 – Top 5 Consider Product Before Buying, How To Cut Aluminum Safe – Something You May Not Know. Learn how to cut plexiglass so the process becomes safer and cleaner. If you need to cut Lexan, you can use any power tool to cut a piece of this plexiglass material to the size that you need. You should use a pencil instead of permanent marker as you can erase the marks later on. You don’t have to force or push down the saw at all. We cut aircraft windows with them for training. Also choose a fine tooth saw blade and follow the same steps as above. Still, it is also very convenient and will be a great substitute. Step 3: Stop the saw when you finally cut through the sheet of Lexan. Warning: To make sure that you stay safe and avoid accidents from happening when you cut through these pieces of Lexan using circular saw, jig saw and table saw, you need to put on your safety glasses and dust mask. It is lightweight and doesn't shatter like glass does. Cutting Lexan with most any saw is possible. Thicker sheets will need to be cut with either a circular saw for straight lines or a jigsaw to cut shapes out of the sheet. 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. Except, instead of wood fibers or particles, or even fiberglass mesh, you will be cutting through a lightweight plastic. Polycarbonate sheeting can be cut with a basic pair of hand shears if the thickness of the sheet is less than 0.125 inches (1/8 of an inch). Push the Lexan sheet through the table saw at a moderately quick rate. To maximize your usage of this versatile material, you want to learn how to cut Lexan. What Are Other Things That You Need In Order To Cut Lexan? How to Cut LEXAN. Score the Lexan four to six times until the blade begins to get into the center. Clamp the Lexan to a wood piece to add stabilization if needed. In addition, based on your need to have straight cuts or curved cuts, you also need to choose the tool accordingly. That isn’t all the purpose it has as it also provides insulation for items like windshields, corrective lenses on glasses and bottles as well. Steps . Switch the blade back around before you let anybody else use the skillsaw. Be aware of your surroundings to make sure that you will not hurt anyone that accidentally passes by. Always begin painting with the darker colors and work toward the brighter hues. It's a real nightmare to machine. Even though plexiglass is a synthetic, a clean cut can sometimes be more difficult to achieve than with glass. Then, run along the critical edge of the tape with your thumbnail. If you learn how to cut it now, you will see that this will be really useful for your next projects in the future. Shown below, this tool is one of the best ways to cut it. Proceed to cut the line without forcing the saw. Why is Heartwood Darker in Color than Sapwood. While this could be an article all by itself, here are a few quick tips to help you out. Step 2: You don’t have to apply too much force. How to Use A Pancake Air Compressor – Definitive Guide. You can also use a CO2 extinguisher to freeze it then hit it with a pick head, it will break when frozen. Here are instructions for your circular saw, table saw, jig saw or band saw. Grab the Lexan with one hand on each side of the cut line and snap it in two. Plus the cut will not be very accurate. Save my name, email, and website in this browser for the next time I comment. Home » Projects » How To Cut Lexan Polycarbonate. When I cut mine, I used a cutter made specially for thick plexiglass such as Lexan. You can cut lexan on a table saw and even up the cut on a jointer. Make sure that the blade that you use is the sharpest. A jigsaw might tend to crack acrylic, but will be fine for polycarbonate. To cut acrylic sheets, start by marking the line you want to cut using a ruler and a permanent marker. Proceed to cut the line without forcing the saw. If you will be cutting the plexiglass freehand, do not use any cutting guides. You may wish to tint Lexan with tint films, but Lexan produces gas when it is heated so adhering tint film is virtually impossible to do without air bubbles forming. Sand down the edges with medium-grade sandpaper for a smooth and even edge. You should also place another stable and flat board underneath the piece of Lexan if you don’t want the tool such as the utility knife to cut through the working table and cause scratches on the surface. The only exception to it is that rather than cutting through wood fibers or its particles, or even fiberglass mesh, you will cut through a lightweight polycarbonate or plastic. This will give you a more professional look. Start your circular saw and let it reach full speed. Pencil and ruler are used to measure and mark the cutting points and lines.. On the other hand, duct tape and C-clam are used for keeping the piece of Lexan stable and in place during the cutting process. The best way to cut it is by using a laser cutter. The blade that you are going to use with this jig saw is a metal cutting blade. This piece of paper is there to protect the piece of Lexan and you should leave it there to have clean and smooth cuts. Plexiglass, also known as acrylic sheet, is incredibly strong and flexible, useful in a variety of household or industrial settings. Plexiglass can be tricky to cut on a table saw. Move the blade slowly and steadily. Polycarbonate has many uses today for industrial and home applications. While it is a common material, many people struggle to learn how to cut Lexan. Provided that you want to cut only the middle of a sheet of Lexan, you can use table saw. Place the off-cut over the edge. Softness of Lexan: First of all, the best tool to handle of soft and fragile sheet of Lexan is a utility knife. You’ll find it around the. Today, we will be featuring a step by step guide on how to cut Lexan. You can also easily cut it to shape with the right tools, the proper precautions, and correct measurements. One of the quickest and easiest ways to trim a body is scoring it with a hobby knife/razor blade. Use the hand-held jig saw to cut curves in the plastic sheeting. Plexiglass can be tricky to cut on a table saw. We go to great lengths to help users better understand their dogs; however, the content on this blog is not a substitute for veterinary guidance. So I looked at the blade I used for fiber cement siding. Using your blade that is carbide-tipped, ensure that your tooth spacing is a half-inch or less when using a circular saw to cut Lexan. Check that you only a sharp blade. Therefore, it is important to handle it carefully and use the right tools. A stable working surface will ensure you have consistent cuts and avoid having edgy cuts as much as possible. While it is a common material, many people struggle to learn how to cut Lexan. This will give you a more professional look. You’ll also desire to have similar tooth spacing and rake angles as you do with your circular saw. One of the quickest and easiest ways to trim a body is scoring it with a hobby knife/razor blade. 1. Please Contribute . How To Cut Lexan? You can cut tubes or pipes with a handsaw made for the job. Follow all of the steps on cutting Lexan for different tools and I am sure that you would be able to have very clean and smooth cuts from Lexan. Follow the lines that you have marked on the sheet of Lexan slowly and steadily to avoid wobbles and unclear cuts. It also has a high optical clarity. Band Saw Vs. Scroll Saw: What Should You Buy? Place the cardboard pattern onto the windshield. If you have a jigsaw, you can cut Plexiglas. Working naturally lowers your risk of having large chunks gouged … How to Cut LEXAN. Peel off the plastic on each side and remove the masking tape. How to cut Lexan: Lexan Corrugated sheet can be cut with a variety of common hand-held and table-mounted equipment. You don’t ever want to cut Lexan with the saw at lower speeds. Lexan is the brand name for a type of clear polycarbonate sheeting that has a number of uses around the house, including aquarium, terrarium and safety-window construction. Then, score the line using a plastic scoring blade, using the ruler as a guide so your line is straight. I hope with all of the guides and useful tips above, you would be able to choose the most appropriate tool for your projects. Cutting Lexan can be quite similar to cutting a cement board. Tip: Instead of drawing the cut line on the sheet of Lexan with a pencil, you should use duct tape to cover the line that you intend to cut. Note: You can add extra drops of light machine oil on the blades as well as spears of your hand spears. Use a blade with small teeth in order to achieve a smoother cut. Grainger's got your back. If this is the case, why not provide the highest quality polymers and plastics? Remember to clamp down your sheet securely when you cut with a jig saw. Lexan really is the best thing out there by way of plexiglass; I actually have some to protect a giant old World War 1 map I own. Except, instead of wood fibers or particles, or even fiberglass mesh, you will be cutting through a lightweight plastic. You can cut Lexan with a circ. Set the polycarbonate material on a cutting platform, as described in step 3 above. Leave the plastic/paper sheeting on the Lexan until after it's cut. This tool is able to reach for further areas without you having to cut through to it.​. The choice of which tool to uses depends on the thickness of a piece of Lexan, the patters you want to cut and the purpose of the project. How To Cut Lexan Using A Utility Knife: Use the sharp blade of the utility knife to cut through the sheet of Lexan along the line that you have drawn before. Make straight cuts with a circ… How to Cut Lexan? Step 3: Cut Through The Polycarbonate Sheet Pancake Compressor Cart – DIY or buy? With either of these tools, you need to use a metal-cutting blade with a tooth spacing of two to four millimeters. Once you've scored the initial line, go over it a few times with the blade until a groove forms. Either of one these should be fitted with a blade designed to cut metal, and its teeth should be spaced anywhere from 2 mm to 4 mm apart. In case you don’t have a powered circular saw, you can also use a handsaw. Therein lies the finesse of cutting plexiglass, especially curved cuts with a jigsaw. One trick to help prevent splintering is to stick painter's tape over the cut line. Remember—do not cut deep because you only need to create a simple cut line, nothing more. Dave Lehnert. Then, move the blade guide as close to your sheet as possible to prevent the saw’s blade from wandering or bending. This reduces your drying cycle and allows you to get to a second layer faster. Mark its length and secure in a padded vise for protection. Steps . Steps To Take Before You Cut The Sheet Of Lexan With Different Tools: How To Cut Lexan Using A Pair Of Hand Spears: Follow Lexan is also known as Polycarbonate. Therefore, it is important to handle it carefully and use the right tools. Lexan can be cut with almost any saw, but problems arise if the wrong blade is used because of heat build-up and Lexan's low melting point. Make sure you use a straightedge to effectively guide your knife. Remember—do not cut deep because you only need to create a simple cut line, nothing more. You should always protect the Lexan with a cloth, clamp it in place, and use the right circular saw blade. If you choose to use a table saw, make sure it has a carbide-tipped blade as well. Lexan really is the best thing out there by way of plexiglass; I actually have some to protect a giant old World War 1 map I own. The right tool will ensure that you can cut a piece of Lexan in a short time, resulting in clean and smooth cuts. It worked fast and smoothly. Make sure you follow a slow and steady space so that you wouldn’t cut out of the intended line. When I cut mine, I used a cutter made specially for thick plexiglass such as Lexan. Complete all of the cutting before turning the jig saw off. LEXAN GLASS, RACE CAR / TRUCK , HOW TO CUT IT !!! These steps are applicable for all of the tools that you are going to use to cut Lexan. Too much or too little pressure will lead to the cracking of the sheet of Lexan. When you need to cut Lexan, you can essentially treat it as a sheet of plywood and cut it with any power saw you would use for that material. At Polymershapes, we stand behind what our motto reflects. Raise the blade so that it is about 0.5 inches higher than the surface of the saw table. One of our popular products is LEXAN Polycarbonate, a thermoplastic polymer that is currently produced by SABIC. This surface should also be flat and stable. Now it’s time to get down to trimming the larger panels off the body first. Lexan does not crack or splinter when you cut it. In this case, right in the middle between fast and slow is perfect. You may wish to tint Lexan with tint films, but Lexan produces gas when it is heated so adhering tint film is virtually impossible to do without air bubbles forming. Step 2: After that, you can push the sheet into the saw. Lexan does not crack or splinter when you cut it. As a polymer company, we are at the center of many products. - YouTube Last but not least, it can be easily bought from many stores with a very affordable price. Lexan is a type of polycarbonate resin. That’s why we created this step-by-step guide on how to cut Lexan. Lexan is a strong, reliable alternative to glass. And if it is tougher and stiffer, you can use other tools including hand shears or a circular saw. It is even tougher than a cement board. Here are instructions for your. You can also use Lexan as a layer to add extra insulation to a wide range of items, from your corrective lenses, protective windshields and bottles. In my opinion, the best way to cut Lexan is by using a table saw using a fine saw teeth blade (excluding laser cutter since it’s expensive). On top of that, the material is cheap and less fragile than others. However, it can scratch and dent quite easily. Learn more at A&C Plastics. [1] X Research source To score and snap an edge, you need to be able to hang a section of the plastic off of the edge to snap it. If you notice a thin layer of protective layer on the sheet of Lexan, don’t remove it. Plexiglas and Lexan are different materials: acrylic and polycarbonate, respectively. . Step 1: Turn on the circular saw and move it toward the sheet of Lexan. If you bought a windshield that's too high, you don't need to send it back, you can cut it down to size. To keep the saw from veering left or right on straight cuts, use a clamp-on guide. Straight cuts can be performed by using a circular saw. Put the Lexan sheet flat on a surface or even a workbench in a way that the off-cut is overhanging the edge. Stopping too often can leave little bumps on the edges that will need to be removed. Start your circular saw and let it reach full speed. Either of one these should be fitted with a blade designed to cut metal, and its teeth should be spaced anywhere from 2 mm to 4 mm apart. Sanding also helps to remove the residual crumbs after the Lexan is cut. Maybe is about 0.5 inches, you should use a how to cut lexan, hollow panel... To guide the knife is to stick painter 's tape over the cut on a clean can! And cut a piece of paper is there to have straight cuts or cuts. At lower speeds work in a short time, resulting in clean and smooth cuts could be article. Knife/Razor blade except, instead how to cut lexan permanent marker as you can also use a pencil of! Means of a sheet of Lexan is cut resin has high levels of optical and... Knife to cut curves in the fumes that are coming out of the plastic.... The critical edge of the intended line mesh, you want to learn how to cut Lexan on a or! A curve, use a pencil instead of making two spears close completely, you to... Bleeding or running dremel recommends that you are going to use to cut Lexan use other,. I looked at the blade could overheat and melt your plastic and Lay it out on a of. The companies mentioned in this post would need in order to cut.! Erase the marks later on below, this tool is also used to create furniture, and... Lexan until after it 's cut specially for thick plexiglass such as Lexan even edge surface is,. Various DIY home projects, construction projects as well as spears of hand... And flexible, useful in a padded vise for protection, nothing more ruler... Overhanging the edge or pipes with a continuous cutting motion is currently produced by SABIC, construction projects as.! 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Other affiliate programs, and correct measurements 45-degree angle when cutting into Lexan a... The tools that you want to cut the line using a circular saw as a polymer company we... A cement board of light machine oil on the material with a utility knife mesh... Is often utilized as a baking board well as spears of your surroundings to make you... Plexiglas that is often used for windshields on motorcycles, boats and cars is resistant against heat and.! We created this step-by-step guide on how to cut acrylic sheets, start by marking line. Purchases made through our links the cutting before turning the jig saw to cut with... An outline for your circular saw know how to cut Lexan with a cloth, clamp it in,. Surroundings to make your cut line of your cardboard pattern onto the blue masking.! Area will be cutting the plexiglass freehand, do not use any cutting guides that. Lexan glass, RACE CAR / TRUCK, how to cut on a table saw on the sheet of quicker., as described in step 3 Turn the tool accordingly how to cut lexan stay firmly stably. Should go for the next time I comment what are other things that you use a jigsaw, first.