Acrylic glass (plexiglass) is an inexpensive and strong material that can be used for a variety of projects, such as picture frames, tabletops, or a substitute for shatter-resistant glass. This material is also lightweight, affordable, and durable because it does not rot or crack. You can also cut it into the shape you want using the right tools, precautions, and the right measurements. Thin sheets of acrylic glass can be cut and broken with a utility knife or scissor. Thicker sheets will need to be cut by a chainsaw for straight cuts, or a jigsaw to make shapes.
Step
Method 1 of 3: Cut and Break Acrylic Glass
Step 1. Lay down the acrylic glass so that it is flat on the work surface
For a thin sheet of plastic glass that is less than 0.5 cm thick, you will need to cut and break the acrylic easily. Lay a flat acrylic sheet on a table or workbench so that it can be measured and cut on a stable surface.
- Make sure the surface of the sheet is clean and there are no objects that can interfere with work, have the potential to damage, or leave marks on the acrylic glass.
- Make sure you are working on a flat and stable surface so it doesn't wobble.
Step 2. Draw a line with a dry-erase marker (can be erased with a dry eraser) to guide the cut you want to make
While the sheet is lying flat on the work surface, use a ruler as a guide and draw a straight line where the sheet of glass will be cut. Make sure the lines are drawn clearly and don't let the marker smudge.
Use a dry-erase marker so that it can be removed after the acrylic sheet is cut
Tip:
If you make a mistake while drawing, erase the line completely so it can be drawn again. Use a washcloth or wet tissue to remove the marker.
Step 3. Use a utility knife to cut along the marking lines on the sheet of glass
Make sure the acrylic sheet is flat and stable on your work surface. Press the sheet firmly and use a ruler to guide the utility knife as you make markings on the acrylic sheet. Slice the guides 10-12 times, until the recess in the sheet of glass is deep enough.
- You can also use a chisel if the blade is sharp enough to slice through acrylic glass.
- The deeper your cut, the easier the acrylic glass will be to break.
Step 4. Turn over the acrylic sheet and nick the other side
Once you've formed a recess on one side of the sheet of glass, hold the acrylic by the side and flip it over so that the recess is now facing down. Slice along the same guidelines to make the acrylic glass easier to break. Continue to draw the line until a recess also forms on this side.
Be careful when picking up the sheet of glass so that it doesn't bend or warp before it's ready to be broken
Step 5. Position the sheet of glass so that the cut part hangs over the edge of the table
Once you have finished slicing the acrylic sheet, position it to make it easier for you to break it. Move the acrylic so that the part you want to break is hanging over the edge of the table.
Make sure that the entire part you want to break is hanging over the edge of the work surface
Step 6. Clamp the sheet on the surface so it doesn't move
Use C clamps or springs and attach them where you don't want to cut them. Install the clamps in such a way that the acrylic sheet cannot move on the work surface.
Be careful not to over-tighten the clamp, causing a scuff or divot to the acrylic
Step 7. Break some of the acrylic glass sheet
While the sheet of glass is sandwiched against the work surface and not moving, press the part of the sheet hanging off the edge quickly down to break the acrylic glass. The acrylic sheet should snap neatly along the previously sliced line.
- You can hold the part of the glass above the work surface with one hand, and press the part of the glass that hangs down with the other.
- If the sheet of glass doesn't break neatly in the guideline, use a utility knife to cut along the recess until the edges are neat.
Method 2 of 3: Straight Cutting Using a Circular Saw
Step 1. Use a circular saw with a carbide-tipped blade
Thicker sheets of acrylic glass need to be cut with a chainsaw. Make sure the serrations are evenly spaced and the same size and shape. The carbide tipped blade is designed to cut metal strong enough to cut acrylic without blowing dust or debris into the air.
- A small number of serrations will minimize the quantity of dust or debris generated from cutting acrylic glass.
- You can also use a blade specifically designed for cutting acrylic glass.
Warning:
Small particles of acrylic glass can damage the eyes. Wear eye protection when cutting sheets.
Step 2. Place the sheet on the sawhorse and mark the parts you want to cut
Place the sheet of glass on the easel so you can cut the acrylic while keeping it flat and motionless. Use a ruler or ruler to draw a straight line to mark the cut line you want to make. This line will be the guide line so make sure it is perfectly straight and clearly visible.
Use a dry-erase marker so you can easily remove the marks if they need to be repaired
Step 3. Align the guide lines on the saw with the drawn line
Circular saws have markings or slits that allow you to see where the saw will cut. Align these guides with the lines made in the acrylic glass.
Make sure the acrylic sheet is solid and won't wobble or move
Step 4. Bring the saw to its full speed before cutting the sheet
The saw blade must rotate at full speed before touching the sheet to produce a smooth and even cut. Turn on the saw and let it spin until it reaches its full speed.
Splitting the sheet before the saw reaches full speed can cause the blade to be caught by the sheet of glass, resulting in a rough and uneven cut
Step 5. Gently push the saw and smooth the acrylic glass
Use the markings on the circular saw and the sheet of glass to guide the saw blade toward the acrylic glass. Push the saw steadily to prevent it from stumbling.
- If the saw is stuck or stuck, you may be pushing the saw too fast. Stop pushing and allow the saw blade to return to its maximum speed, before pushing the saw back against the acrylic sheet.
- Make sure the two acrylic glass beaks are fully balanced on the easel so they don't fall off when you're done cutting.
Method 3 of 3: Using a Saw to Cut Shapes
Step 1. Use a jigsaw to make round cuts on the acrylic glass
The jigsaw has the appearance of a bandsaw but is shorter and cuts up and down. You can also use a jigsaw to cut straight or circularly, making it perfect if you want to make special shapes on acrylic glass.
- Use a blade saw without a top cover with fine serrations to cut acrylic glass.
- Have some extra blades nearby in case they need to be replaced while you're sawing acrylic.
Step 2. Place the acrylic glass sheet on the easel
Use the easel as a work post to hold the sheet together while you cut it. Spread the sheet so that it is firm and stable on the easel.
Check the acrylic sheet to make sure it doesn't shift or wobble before cutting
Step 3. Mark the sheet with a dry-erase marker to guide the saw
You will need to make markings to guide the saw, especially if you are going to cut unusual shapes. A jigsaw will allow you to make certain shapes, but you will still need clear markings as a guide. Use a dry-erase marker to outline the shape you want to cut.
Dry-erase markers make it easy to erase marks when you're done or when you need to fix them
Tip:
If you're cutting out designs or shapes, use a stencil or circular object to help create neat marks.
Step 4. Wear safety glasses to protect your eyes
The sawing process can blow debris or small particles into the air. These particles and debris can injure the eyes if they get inside. Before starting sawing, you must wear safety glasses.
Make sure the safety glasses fit snugly on your head so they don't fall off while sawing
Step 5. Make a hole in the acrylic sheet that is the right size with a saw using a drill
The jigsaw needs an opening to fit through the sheet of glass. So, make a hole in the acrylic glass using a drill and a rock drill bit large enough so that later the saw blade can fit in. If you are going to cut a curved or curved shape, drill a hole at the point of the narrowest bend. This helps the saw blade turn when it reaches this bend.
If you can't turn easily, the blade may bend or even break the acrylic
Step 6. Insert the saw blade into the hole and wait until the speed is maximum
Once the saw blade is inserted into the drilled hole in the acrylic glass, turn on your jigsaw. The jigsaw blade moves slower than a circular saw or bandsaw so you will need to wait for it to reach maximum speed before cutting.
- If the saw is used to cut before it reaches full speed, the blades can stutter and bend or even damage the jigsaw.
- There is a chance the saw blade will break and injure you. So, work with extra care.
Step 7. Gently push the jigsaw to cut the acrylic glass sheet
Work carefully so the saw doesn't jump off the acrylic sheet. Follow your guide line carefully and slow down when turning. If you hear the sound of the saw blade stuttering or squeezing, slow down and increase it so that the blade returns to its highest speed, then continue pushing the jigsaw to cut the acrylic glass.
