The method and tools used to cut acrylic plexiglass vary depending on its thickness. Below are the recommended cutting methods for different thicknesses of acrylic sheets:

1. Thin acrylic plexiglass (Less than 3mm)

For acrylic sheets thinner than 3mm, the following methods are ideal:

• Utility Knife Cutting: For thinner sheets, you can use a utility knife. Score along the cutting line multiple times until a deep groove forms. Then, place the acrylic sheet on a stable surface and apply pressure to snap it. This method is suitable for straight cuts but is not ideal for intricate curves.

• Laser Cutting: Laser cutting machines are perfect for thin sheets, providing precise and smooth cuts. This method is contact-free, avoiding cracks that can result from excessive pressure.

2. Medium Thickness acrylic plexiglass (3mm to 10mm)

For acrylic sheets with a thickness ranging from 3mm to 10mm, the following tools are recommended:

• Circular Saw (Fine-tooth Blade): A circular saw with a fine-tooth blade is effective for cutting medium-thickness acrylic sheets. Ensure you use a blade designed for plastics to avoid melting. Keep a steady cutting speed and apply even pressure to achieve clean cuts.

• Table Saw: A table saw is suitable for precise straight cuts. Depending on the acrylic sheet thickness and required cutting angle, choose the appropriate blade and settings.

3. Thick acrylic plexiglass (Above 10mm)

For acrylic sheets thicker than 10mm, more advanced methods are required:

• Circular Saw (Special Plastic Cutting Blade): A high-quality circular saw with a fine-tooth blade can be used for cutting thick acrylic sheets. Maintain the appropriate cutting speed, as high speeds may cause rough edges or melting.

• CNC Milling Machine: For extra-thick acrylic sheets, a CNC milling machine offers precision and control for complex shapes. It cuts layer by layer, making it suitable for thick material processing.

• Laser Cutting: Laser cutting machines can be used for thick acrylic sheets but require higher power to ensure effective cutting. The cutting speed is slower, and careful attention should be given to heat buildup during the process.

4. Cutting acrylic plexiglass – Additional Tips:

• Cooling: During the cutting process, especially for thicker acrylic sheets, it’s important to avoid excessive heat that can cause surface melting. Cooling fluids or an air compressor can help maintain the material’s temperature.
• Edge Finishing: After cutting, the edges of acrylic sheets may be rough. Use sandpaper or a polishing tool to smooth out the edges for a clean, polished finish.

By choosing the right tools and methods based on the thickness of the acrylic sheet, you can achieve precise cuts and ensure a high-quality result for your project.