How to Cut Lexan Easily and Safely

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Want to know how to cut lexan easily and safely? Check out this blog post for tips and tricks on the best way to cut lexan.

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Polycarbonate, or Lexan, is a durable thermoplastic used in a variety of applications, from security windows to bulletproof glazing. It’s also used frequently in model-making and other crafts, as it can be easily cut and shaped with the right tools.

While Lexan can be cut with a variety of different power tools, the safest and easiest way to do it is with a handheld rotary tool fitted with aabrasive cutting disc. This guide will show you how to do it.

Tools and Materials Needed

To cut Lexan, you will need the following tools and materials: a straight edge, a sharp utility knife, a fine tooth saw, and a piece ofLexan. You will also need a work surface that is large enough to accommodate theLexan sheet.

##Heading:Step One
Using the straight edge, mark the Lexan where you want to make your cut. Make sure that the line is straight and that you are comfortable with the measurement. Once you have made your mark, use the sharp utility knife to score the Lexan along the line that you have just made. Apply pressure evenly as you move the knife along the surface of the Lexan.

##Heading:Step Two
Once you have scored the Lexan sheet, place it on your work surface so that the area that you just cut is hanging over the edge. Apply pressure to the side of the sheet that is hanging over the edge of the work surface and snap it off. You may need to use a little bit of force to do this. If necessary, use a fine tooth saw to finish cutting through any remaining pieces of Lexan.


Preparation is critical when learning how to cut Lexan easily and safely. This material can be splits into numerous layers, which means that scoring it with a knife creates the potential for shattering. You’ll need to use a sharp pair of scissors to make a series of evenly spaced cuts that are just deep enough to penetrate the top surface.


Safety is the number one priority when working with any type of power tool, and that includes when you’re cutting Lexan. This durable material is often used for bullet-proofing glass, so it’s important to take the same precautions you would with any other type of glass. Here are a few tips to help you cut Lexan easily and safely:

1. Use a sharp blades – dull blades can cause the Lexan to crack or shatter.
2. Start with a clean, even cut – this will help prevent the material from cracking or shattering.
3. Apply even pressure – too much pressure can cause the Lexan to crack or shatter.
4. Use a saw with a fine-toothed blade – this will help prevent the material from cracking or shattering.
5. Work slowly and carefully – rushing can cause the Lexan to crack or shatter.

Finishing Up

Now that you have cut your Lexan sheet, you will need to finish the edges. The best way to do this is with a router and a 1/4″ roundover bit. Set the router up so that the bit is sticking out about 1/8″ and adjust the depth so that it will take about 1/32″ off of the edge of the material. This will create a nice, finished edge that will be safe to handle.

Tips and Warnings

Use a fine-toothed saw blade when cutting Lexan. A standard wood-cutting blade will cause the Lexan to crack and shatter.

Wear gloves and eye protection when working with Lexan. The material can be very sharp, and small pieces can break off and cause injury.

Work in a well-ventilated area when cutting Lexan. The material gives off fumes that can be harmful if inhaled.


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