Q&A for How to Cut Polycarbonate

Check method 4 on how to cut polycarbonate with a jigsaw. Refer to the 4 drawings to see how to set up.

Use of any abrasive method is generally not recommended. A considerable amount of dust would be generated. Even with protective gear, potential particles could be inhaled. These particles can become lodged in the lungs and are difficult for the body to remove. Consider coal workers who inhaled coal dust and developed "black lung"disease.

Probably not. Polycarbonate is a really sturdy material and it may be too thick and too tough to cut with a pair of scissors. However, you may be able to score and snap the polycarbonate using your scissors if it's thin enough. Lay the plastic out on a table or saw station. Any surface can work as long as the surface is flat, stable, and has an edge. Mark the cut line with a straight edge and marker on the sheet of plastic. Line your straight edge up with the cutting line. Hold the blade of the scissors against the straight edge on the edge of your line at the top. Press down with moderate pressure and slide the blade of your scissors at a 45-degree angle along the cutting line. To snap the sheet, brace the center of the sheet on the table by pressing down with your nondominant hand. Keep the sheet of plastic still and grip the excess section that you scored with your dominant hand. Lift it up a little bit and press down with firm pressure to break it off along the cut line.

For a thick sheet of plastic, a circular saw is the best way to get the job done. Place your plastic on your work station or saw horses. There will be some plastic dust from the cutting, so set your station up in a well-ventilated area. Use a ruler or yardstick as a straight edge to mark your cutting line with a grease marker, permanent marker, or dry erase marker. Wear protective goggles to protect your eyes from any shards of plastic and put on a pair of thick gloves to protect your hands. Slide your straight edge against the edge of the base plate. Hold the saw’s handle with your dominant hand and then move your other hand aside and brace the straight edge to keep it still. Guide the saw as it slides all the way through the entirety of the cut. As you move forward, slide your free hand up the straight edge so that it follows the saw. Keep bracing the straight edge and slide the base plate against it until you’ve gone all the way through the line that you’re cutting. Let the excess piece fall to the floor. You can then stop the saw and unplug it when you're finished.

Yes, a sharp utility knife like an X-acto knife can score thin sheets of plastic so you can then snap the sheet along the cut line. Start by laying your plastic out on a flat surface like a table or workstation. easure any cuts that you want to make with a measuring tape and use a straight edge to keep your line straight. Hold the straight edge directly against the line that you plan on cutting and use a marker to mark a line you can use to guide your cuts. Then, line up your straight edge with the cutting line and run your utility knife down the length of the cutting line. You can also flip the sheet over and cut along the line on the other side if needed. Then, place the edge of the sheet over the table, lift it up and then push it down really hard to snap the plastic along the cut line.