To cut plexiglass at home, use a scroll saw or a circular saw equipped with a fine-toothed blade. The scroll saw produces less heat than other saw types, reducing the chances of melting the plexiglass, while the fine-toothed circular saw reduces chipping along the cut edges.
- Prepare the plexiglass
Mark the desired cut line on the plexiglass piece using a straightedge and a pencil. Put on a pair of safety goggles to protect your eyes from chipping or splintering plastic, as well as a long-sleeve shirt and safety gloves to protect your arms and hands. Use a variable speed saw for this project. Select a circular saw with fine crosscut teeth if cutting a large piece of plexiglass, or a scroll saw for smaller pieces or curves.
- Cut the plexiglass
Place the plexiglass onto a flat cutting surface. Start the saw at a slow speed to avoid melting the plexiglass as it is cut. Cut along the pencil-marked line, increasing the speed of the saw until it moves smoothly through the plexiglass without melting it or causing excessive chipping or roughness along the edge. Cut through the plexiglass until reaching the end of the cut line, then remove the saw and turn it off.
- Finish the edge
Smooth out any chips or roughness from the cut edge of the plexiglass with fine-grade sandpaper. Wipe the edge with a clean cloth to remove any plastic residue.