How to Cut Polycarbonate Sheets

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Polycarbonate is a clear, strong, and lightweight plastic that is widely used in a variety of industries. It is often used in place of glass in a variety of applications.

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Polycarbonate is a versatile, tough plastic used for a variety of purposes, including bullet-proofing and engineering. It typically comes in sheets, which can be cut with a few different types of saws. A fine-toothed handsaw or jigsaw can be used for straight cuts, while a circular saw is better for cutting long, curved lines. You can also use a utility knife or scoring tool to make clean, straight cuts in thinner sheets of polycarbonate.

Tools and Materials Needed

In order to properly cut polycarbonate sheeting, you will need a few specific tools and materials. You will need a sharp utility knife, a straight edge, and a fine-toothed saw. You will also need to use polycarbonate-specific cutting fluid, which can be purchased at most hardware stores. Finally, you will need to use a soft cloth to clean up any debris left behind by the cutting process.

When cutting polycarbonate sheeting, it is important to take your time and make sure that your cuts are straight and even. If your cuts are not straight, the edges of your polycarbonate sheeting will be weak and more likely to break.

Cutting Polycarbonate Sheets

Polycarbonate is a very durable material that is used in a variety of applications, from bullet-resistant windows to eyeglass lenses. However, because it is so tough, it can be difficult to cut without the proper tools and techniques. In this guide, we will show you how to cut polycarbonate sheets properly to avoid damage and get clean, precise cuts.

The first step is to choose the right type of saw blade for your polycarbonate sheet. A standard wood-cutting blade will not work well on polycarbonate; you need a blade that is specifically designed for cutting plastics. There are two main types of saw blades that are suitable for cutting polycarbonate: carbide-tipped blades and high-speed steel (HSS) blades. Carbide-tipped blades are more expensive than HSS blades, but they stay sharper for longer and they produce cleaner cuts. If you can afford it, we recommend using a carbide-tipped blade.

Once you have the right type of saw blade, you need to make sure that it is sharpened properly. A dull blade will cause the polycarbonate sheet to crack or shatter, so it is important to use a sharp blade. If you are using a carbide-tipped blade, you can sharpen it yourself with a diamond sharpening stone; if you are using an HSS blade, you will need to take it to a professional sharpener.

Now that you have the right type of saw and a sharp blade, you are ready to start cutting your polycarbonate sheet. The best way to cut polycarbonate is with a power saw; hand saws can be used, but they are much more likely to cause damage (cracks or shattering) than power saws. When cutting with a power saw, use a slow speed and moderate pressure; too much pressure can cause the polycarbonate sheet to crack or shatter, while too much speed can cause the blade to overheat and damage the edge.

Once you have cut your polycarbonate sheet into the desired shape, you may want to smooth the edges with sandpaper or a file. This is not strictly necessary, but it can give your finished project a more polished look.

Finishing the Edges

After the polycarbonate sheet is cut to size, the next step is to finish the edges. There are several ways to do this, but the most common method is to use a router. A router is a hand-held power tool that spins a small cutting bit at high speed. The bit cuts away material as it spins, leaving a smooth edge.

To use a router, first set the depth of the cut. This is the distance that the router will sink into the polycarbonate sheet as it spins. The depth of the cut will determine how thick the finished edge will be. Generally, you want the finished edge to be about 1/8 inch thick.

Next, clamp the polycarbonate sheet down so it won’t move as you’re working. Then, start the router and slowly guide it along the edge of the sheet. Keep the router moving steadily so that you get an even, consistent cut.

Once you’ve finished all four edges, your polycarbonate sheet is ready to use!

Tips and Tricks

Polycarbonate is a tough, transparent plastic used in a variety of applications, from bullet-resistant windows to illuminated signs. Though cutting polycarbonate may seem like a daunting task, there are a few tricks you can use to make the job easier.

First, it’s important to choose the right type of blade for your saw. A carbide-tipped blade will stay sharp longer than a steel blade and is less likely to chip the polycarbonate. Second, use a fence or clamps to secure the polycarbonate sheet in place before cutting. This will help prevent the sheet from vibrating and reduce the chance of the blade chipping or breaking the polycarbonate.

When cutting polycarbonate sheets, it’s important to go slowly and use light pressure. resist the temptation to force the blade through the material; letting the blade do the work will result in a cleaner cut and less damage to both the blade and the polycarbonate sheet. Finally, be sure to clean any dust or debris from the cutting area before moving on to avoid scratching or marring the surface of the polycarbonate.


The best way to cut polycarbonate sheets is to use a power saw with a fine-tooth blade. You can also use a hand held circular saw, but it is more difficult to control the depth of the cut. If you are cutting thick sheets, it is best to use a table saw. It is also possible to score the sheet and then snap it along the scored line, but this is more difficult to do with thicker sheets.


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