Lexan, plexiglass, and acrylic are all similar materials known as polycarbonates. These materials are commonly used in building and DIY projects. With a little bit of knowledge, these sheet materials are easy to work with, but if approached with the wrong technique, they can crack and lose their sleek appearance.
This article will teach you how to cut Lexan so it can be installed correctly.
Can Lexan Be Cut Without Cracking?
With the correct technique and tools, Lexan can be cut without cracking.
Before we dive into more detail, you should note that Lexan is the name of the brand, not the material. But as with many other brands, Lexan has become synonymous with the product for some people.
In some cases, people use the term Lexan to describe a different material, such as plexiglass or acrylic. As explained in the introduction to this article, they are similar products called polycarbonates, but they are different from Lexan.
If you thought a sheet of acrylic was Lexan, then you’d be at a much higher risk of cracking the sheet. Some more terms to look out for are Lucite and Perspex. It’s important to properly research your material if you don’t want it to crack.
Because some people often use the terms Lexan and acrylic interchangeably, they assume that Lexan cracks as easily as acrylic can. In fact, Lexan will not crack anywhere as easily as acrylic will.
Is Lexan Easy to Cut?
Lexan is quite easy to cut, as long as you have the right tools and knowledge. In fact, some people approach cutting Lexan exactly the same as if they were cutting wood-based sheet material, such as plywood. In some ways, this approach can work, but to get the best out of your materials, you must treat Lexan for what it is, a polycarbonate sheet, not a sheet of plywood.
If the Lexan is not visible in your final product, then it’s considerably easier to cut. This is because a lot of the difficulty cutting Lexan comes down to not damaging the material visually. Unlike plywood, scratches can’t get sanded out of Lexan.
5 Ways to Cut Lexan
There are a few different tools you can use to cut Lexan. If you are not a professional, you probably will only have access to one or two of the tools listed. If you don’t have access to any, consider hiring one for a short period of time, using the correct tool is vital to cutting anything, not just Lexan, properly.
1. Circular Saw
A circular saw is a handheld power tool with a motor that spins a circular blade, which cuts through the material. To cut Lexan successfully with a circular saw, you need to set up your work area correctly. Make sure there is enough space for the sheet to get laid down flat on a workbench and for you to maneuver around it without obstruction. You also want to ensure there is sufficient ventilation or use an extractor to remove harmful particles from the air.
First, use a sharp pencil to make a straight line along the cut you want to make. If possible raise the sheet up so the Lexan is supported on either side of your cut line, this is to prevent you from cutting through your bench.
The depth of the cut can be adjusted on a circular saw. With the power off, adjust the saw to have as little of the blade cutting through the material as possible. However, you want the gullet of the blade completely clearing the material it is cutting through. If you look at the saw blade, the gullet is the bottom point between two blade teeth.
Put on your PPE and line up the saw with your pencil marks. Before cutting, if you have spare or waste material it’s advisable to do a test cut. This will give you an idea of how the material responds to the blade.
Align the saw on your cut line, keep the blade off of the material and start the saw. You don’t want to start the saw in contact with the material because it could kick back or damage the Lexan.
Slowly, with a controlled and steady movement, move the saw through the material along your mark. Keep your body and fingers well away from the blade and the underside of the sheet. As you get to the end of the cut, there could be a lot of weight pulling at a small amount of material, try to support the already cut area of material so it doesn’t pull, warp, or crack the sheet.
2. Table Saw
A table saw is another form of circular saw. The blade is mounted onto a table, with the cutting edge protruding through the top face of the table, known as the ‘bed’. A table saw also has a rip fence (and on larger saws a sliding bed) with a cross-cut fence to support larger material through cuts.
With the material marked out and PPE on it’s time to cut the Lexan. The blade must protrude through the material far enough to see the bottom of the gullet. The sheet must be secure, stable, and flat on the bed. If you are cross-cutting, push the Lexan square against the cross-cut fence and hold it securely whilst pushing the sheet through the blade.
If you are ripping the board along its length, extra caution must be taken to feed the board through the cut. Set the rip fence so its final point goes no further than 1/3 of the blade diameter. This is to stop the material binding between the fence and the blade, which could cause kickback.
Push the material through and when you get near the blade, use push sticks for the final sections. Never stand directly behind the material as it goes through the saw, stand to the side of it. If you are standing behind it and there is a kickback, you are in danger of harm.
3. Jigsaw
A jigsaw is a reciprocating blade that moves up and down. Because the blade is a lot thinner and less wide than circular blades, a jigsaw can do curved cuts. While people do use them for straight cuts, a jigsaw tends to move more than tools with larger blades.
A jigsaw blade will either cut on the downward or the upward stroke. If the Lexan has one important, visible face, this should be on the first side that the blade contacts. For example, if you have a downward cutting blade, the important face should be up. If you have an upward cutting blade, the important face should be down.
Mark the Lexan out with a pencil and put on your PPE. Bring the tool up to the material and start it up before the blade makes contact. Slowly guide the blade through until the material is cut.
4. Knife
If you have a thin enough sheet of Lexan, it’s possible to cut it with a utility knife. To do this, you need a new sharp blade in the knife, a straight edge to run the knife along, and a couple of clamps.
Clamp the straight edge along the line that you want to cut. Keep the knife blade flat along the straight edge and repeatedly score into the Lexan. You want to make as deep a cut as possible into the Lexan, whilst also trying to keep the knife from straying out of the original cut line.
Once the scoreline is deep enough, reposition the Lexan so the straight edge and clamps are on the other side of the cut line and overhang the second side over the bench. Firmly push down on the side overhanging the bench, which should snap along the score line. If the cut is not clean, then score deeper on the next attempt.
5. Oscillating Multi-Tool
A multitool is another tool with a reciprocating cutting action. If you have a small amount of Lexan that needs to be trimmed, particularly if the sheet is already in position, a multitool can take off small amounts.
With a sharp blade, slowly bring it onto the cutting line and move it through the material until it has completed the cut. Multitool blades are designed to cut different materials so try to find one specifically for plastics.
Mistakes to Avoid, Tips & Tricks
In this section, we’ll explain some of the common mistakes people can avoid, as well as some good bits of information to improve the outcome of your project.
1. Use the Correct PPE
Safety is the most important aspect of any job. Your PPE should include safety glasses, ear defenders, and steel toe-capped boots. Alongside this, the room should be well-ventilated with an extractor and a mask worn.
2. Protect the Material
Lexan will scratch quite easily so it’s important to protect it as much as possible. When handling it, don’t drag it, lift it. If it’s stored on an edge, put a blanket down on the floor so the edge doesn’t chip.
Also, consider taping along the cut line so the foot of a jigsaw or circular saw doesn’t directly contact the face and scratch it.
3. Cut On the Waste Side
When you have marked out your material, mark the side of the line that you want to keep and the side that is waste. If you cut on the wrong side of your marked line, your piece will end up too short.
4. Measure Twice, Cut Once
Always double-check your measurements before cutting. It might seem like you’re saving time and getting things right. But it only takes one mistake for that effort to be wasted. Measure twice, cut once.
5. Support the Sheet Along Its Length
Large thin sheets can be quite flexible. The movement in the sheet can cause the material to bind or pinch on a circular saw or jigsaw as it moves through.
By supporting the Lexan along its entire length, it is less likely to sag, drop, and create unwanted movements that will impact the accuracy of your cut and how clean it is.
6. Use Sharp Tools
Saw blades are cutting tools. This means that the very tip of the blade slices through the material. If the blade isn’t sharp it will work more like an abrasive, which will create burn marks and chipping. If you want a clean cut, use a sharp blade.
Alongside this, try to see if you can find any blades designed specifically for plastic that are compatible with your tool.
7. Use a Rail or Straight Edge
Getting a truly straight cut freehand with a circular saw or a jigsaw is very difficult and for most people impossible. To help create as straight a line as possible, consider using a rail or a straight edge to guide the saw along the cut.
Summary
Lexan has a lot of applications and can be a great addition to a build. Cutting Lexan doesn’t have to be difficult as long as you are careful to not damage and scratch the sheet. If you have the correct, sharp tools, and set up for the cut thoroughly, you will have no problem getting a clean, accurate edge.