The Best and Safest Ways to Cut Through Plastic

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Learn how to safely slice through thick plastic using these hacks

Co-authored by Jacob Pischer and Bertha Isabel Crombet, PhD

Last Updated: March 31, 2025 Fact Checked

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Sawing

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Drilling Holes

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Using String

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FAQ

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Video

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Q&A

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Warnings

Durable, thick plastic is used to make PVC pipes or to build items like RC cars and hobby miniatures. If you need to cut through it, there are several different methods you can use depending on the type of plastic. Whether you use a fine-toothed saw, a hacksaw, or a non-melting table saw blade, here is a comprehensive guide to cutting through thick plastic safely and efficiently, including expert advice from handyman, Jacob Pischer.

Cutting Thick or Hard Plastic

Cut through thick plastic with a fine-toothed saw, jigsaw, or a non-melt blade. You can also use a drill bit to drill holes in the plastic you want to cut through, cutting from one hole to the other. Additionally, you can use a string to cut through the plastic by moving the thread back and forth to make an incision.

Section 1 of 4:

Sawing Thick Plastic

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1
Cut through plastic with a fine-toothed saw. According to Pischer, when using a fine-toothed saw , clamp the plastic you’re cutting to a table or work bench with a C-clamp. Saw using the full length of the blade, and move the saw in smooth, quick back-and-forth motions through the material you’re cutting. Using a saw with fine, small teeth will allow you to cut through thick plastic precisely and without destroying the plastic itself. ^{[1]
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Expert Source

Jacob Pischer
Home Improvement Specialist

Expert Interview. 4 September 2020.}
- While all saws will be able to cut through plastic, saws with large teeth will leave the plastic torn or shredded. ^{[2]
  X
  Expert Source
  
  Jacob Pischer
  Home Improvement Specialist
  
  Expert Interview. 4 September 2020.} Some of these fine-toothed saws look like a knife or straight-razor and can easily be used with one hand. ^{[3]
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  Research source}
- A selection of fine-toothed saws may be available for purchase at hobby stores, since they’re commonly used to cut plastic models and die-cast figurines.
2
Cut through plastic with a jigsaw. When cutting with a jigsaw , hold the object you’re sawing firmly, or use a C-clamp to hold it on a table. Squeeze the trigger, so the blade is moving before you touch it to the plastic. Hold the saw’s handle steady, and use firm pressure to press the blade through your plastic.
- A jigsaw will work best if you’re cutting heavy-duty plastic, including PVC pipe. ^{[4]
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  Research source} The blade of a jigsaw is about 8 inches (20 cm) long, so won’t lend itself to detailed cutting (for example, if you want to cut out a small circle of plastic).
- You can purchase jigsaws and other fine-toothed saws at your local hardware store.
- Pischer notes that a Sawzall , or reciprocating saw, is another great tool for cutting plastic. ^{[5]
  X
  Expert Source
  
  Jacob Pischer
  Home Improvement Specialist
  
  Expert Interview. 4 September 2020.}
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3
Use a table saw with a non-melt blade to cut through thick plastic. Start the table saw running, and set the plastic you want to cut on the flat surface of the saw table. Hold the plastic by its sides, and slowly push it forward until it engages the blade . Continue to push the plastic forward in a slow, steady motion, until the blade has cut through the entire plastic object.
- If you’re cutting through thick plastic with a table saw, the heated saw blade may melt the plastic. Avoid this by cutting through heavy-duty plastic with a non-melt blade, which will not heat up enough to melt the plastic material. These blades will have evenly-spaced teeth which are set close together. ^{[6]
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- Non-melt table saw blades should be available for purchase at a nearby hardware store. ^{[7]
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  Research source}

Section 2 of 4:

Drilling Holes to Facilitate Cutting Plastic

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1
Select a small drill bit. It’s often tough to cut directly through thick plastic, even with a saw or a sharp knife. If you drill out a series of small holes in the plastic you’re planning to remove, you’ll have an easier time cutting the plastic. To do this, you’ll need a power drill and a small drill bit . ^{[8]
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Research source} Choose a drill bit that’s no larger than ¹ ⁄ ₈ inch (0.32 cm) in diameter.
- If you don’t have an electric power drill and drill bits of varying sizes, you can purchase them at a local hardware store.
2
Drill at least 6 holes in the plastic you want to remove or cut through. Use the small drill bit to drill 6–10 holes in the section of plastic you’re trying to cut through or remove. Make these holes as close to one another as possible. This will weaken the structure of the plastic. ^{[9]
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Research source}
- This method will be most effective if you’re doing detailed cutting—for example, on a hobby miniature.
- If you’d like to cut through very large sections of plastic, you can do so by drilling small holes throughout its surface. This method could even work when cutting heavy PVC pipe. The process will be painstaking and time consuming, but it will allow you to cut precisely.
3
Cut from one hole to the next. Use a hobby knife and cut through the plastic that remains between the holes that you’ve drilled. It may still be tough to cut through the thick plastic. Since you’ll have removed a lot of the connecting material, though, the plastic you’re cutting will be weak and already partially removed. ^{[10]
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Research source}
- Utility knives are also often called hobby knives. They can be purchased at any craft or hobby-supply store.
EXPERT TIP

Jacob Pischer
Home Improvement Specialist
Jacob Pischer is a Home Improvement Specialist and the Owner of Helpful Badger, a home repair service in Portland, OR. With over four years of experience, Jacob specializes in a variety of handyman services including pressure washing, cleaning gutters, repairing drywall, fixing leaky plumbing fixtures, and repairing broken doors. Jacob studied at Madison Area Technical College and has a background in real estate investment.

Jacob Pischer
Home Improvement Specialist

The saw you use needs to have a really fine tooth, so, even a handsaw with really fine teeth would work well. That'll work better than anything that's designed to cut wood. If it is designed to cut wood, its teeth are way too big and it has too big of a grip, so, it's just going to rip your plastic to shreds.

Section 3 of 4:

Slicing Through Plastic with String

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1
Test your string’s durability. You’ll need a section of string about 2 feet (61 cm) long to cut through plastic. Jerk your hands outward with medium force while holding the string. It if flexes slightly and doesn’t snap, it’ll cut through plastic. ^{[11]
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Research source}
- You can purchase cotton or polyester string at any quilting or hobby store.
2
Clamp the plastic firmly between your knees. The plastic that you’re cutting through needs to be held steady while you use the string to slice through it. Hold it tightly between your knees, since you’ll need both hands free.
- Depending on the size and shape of the plastic, you could also use a C-clamp to hold it to a worktable. This is risky though, since if you exert too much pressure with the clamp, the plastic could break.
3
Work the thread back and forth to start a small incision. It’s best if you can set the thread in a corner or along an edge of the plastic, then begin to slide it back and forth. After a few moments, the thread will have cut a tiny groove in the plastic. Set the thread in this little groove and continue to work it back and forth. The groove will lengthen and eventually cut through the plastic. ^{[12]
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- This is a slow, painstaking process. Cutting through thick plastic with thread —for example, when customizing an RC car or working with hobby models and miniatures—is effective, but can take hours.
4
Replace the string if it gets hot or frayed. Continue working the thread back and forth until you’ve cut through the plastic. If you notice that part of the thread has become hot (due to its friction with the plastic), you may need to use a new section of thread. Hot thread is likely to snap. Roll a few more inches off of the spool, and continue cutting. ^{[13]
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Research source}
- The plastic that you’ve sliced through should have a very smooth, clean break without any rough or jagged spots.

Section 4 of 4:

FAQ

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What is the best tool to cut plastic containers with? The best tool to cut through plastic— especially thick plastic— is a saw. The three best options are a fine-toothed saw, a jigsaw, and a table saw. Jigsaws and table saws are perfect for cutting through thicker and larger pieces of plastic, while fine-toothed saws offer the cleanest cuts. ^{[14]
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- You will likely have to use a deburring tool to smooth out sharp edges created by a jigsaw or table saw.
2

How do I cut plastic without cracking it? The best way to cut through plastic without cracking it is to drill small holes and then use a hobby knife to slice through. This is most likely to maintain the integrity of the plastic while still allowing you to cut exactly where you want and to what extent, as safely as possible.
3

Will a hot knife cut through hard plastic? While a hot knife can technically cut though hard plastic, it’s not safe. Using a hot knife exposes you to the risk of burning yourself. Additionally, the plastic could also catch fire, so this method is not advisable. A hot knife is better suited to cut through thin plastic, foam, or other synthetic materials. ^{[15]
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Community Q&A

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Question

My plastic is 0.3 mm thick. I don't have a table saw, jigsaw or a non-melt saw blade. What can I do?

T. Chinsen

Top Answerer

Any toothed blade will cut through plastic. As described in the article, a fine-tooth saw or even a utility knife can cut the plastic. Another possible tool is to use is an unwanted steak knife. Make sure to follow the warnings section to avoid injury.

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Warnings

When using a table saw, keep your hands and fingers clear of the blade, or you could be seriously injured. Avoid wearing loose clothing when cutting with a table saw, and wear protective glasses or goggles.

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Take safety precautions whenever you use a saw or knife. Never cut towards yourself.

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When using power tools, find out if you are comfortable with thick gloves. This can be easy or difficult during emergency as you'll have less reaction time if your gloves get caught in the moving parts.

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Expert Source

Jacob Pischer
Home Improvement Specialist

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The Best and Safest Ways to Cut Through Plastic

Cutting Thick or Hard Plastic

Steps

Sawing Thick Plastic

Drilling Holes to Facilitate Cutting Plastic

Slicing Through Plastic with String

FAQ

Community Q&A

Video

Tips

Warnings

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