How to cut Plastic/Acrylic sheet

How to Cut Plastic & Acrylic with Jigsaw

Cutting Acrylic or Polycarbonate sheets with a jigsaw is not an easy task because Plastic could melt from the heat produced by the jigsaw. However, if done right, you can easily cut through it. Before cutting Plastic, you need to know some important things.

In order to get a fine cut, you have to choose the right Jigsaw blade with the required speed, so it won’t melt the sheet and gives you perfect cuts. When you cut plastic with a Jigsaw, it will produce some heat because the blade runs continuously; however, maintaining the balance is the key to your smooth cuts.

Choosing a blade for your desired work is necessary in order to get smooth fine cuts. Different blades have different TPI for cutting different types of materials and are made of different types of materials such as High-Carbon Steel to cut WOOD, High-Speed Steel for Cutting Metal, and Bi-Metal Blades for cutting Laminates or Soft wood, or Carbide for cutting Ceramic, and many more types to cut different materials. You can see detailed review of different types of Jigsaw blades here.

Keep on reading as we will guide you through the process of how to cut Plastic sheet, Acrylic, PVC, and Plexiglas. What blade to choose, what speed of jigsaw to set, and many more other things. Feel free to comment at the end of the article and let us know if we miss something or if you want us to add some more tips in the article.

Which Blade to Choose:

To cut the Acrylic or Plastic sheet, you will need a Bi-metal blade with 12 or higher tooth counts. Jigsaw Blades designed especially to cut plastic are best to cut through PVC, Acrylic, Plastic sheet, and Plexiglass too. You can find special blades for Cutting Plastic here.

Cutting through Material:

First, set up the plastic/acrylic sheet on the table and use clamps to get a strong grip so it won’t move or vibrate much while you are cutting through it and ruin your material. Clamp it down securely and mark the points where you want to cut. Use masking tape for marking the lines.

Now place the Jigsaw on the surface and press the trigger. Make sure the blade is not touching the material before it starts running at full speed as it can rip off the material or break the blade. Once the jigsaw runs up to its speed, gently push the blade towards the material on marking. Don’t push the blade too hard as it will cause heat and can melt the plastic. Maintain your speed and make a straight cut. You may need to sand the edges after cutting, you can do it manually by sanding files, or you can use a belt sander for that as well. Check out the Best Belt Sander here.

Tip:  If you’re using Jigsaw for the first time on a Plastic or Acrylic sheet, make a test cut on scrap acrylic pieces first and get familiar with the jigsaw speed and blade.