Cut Polycarbonate

Polycarbonate is a lightweight plastic that has high resistance to heat and electricity. It is characterized by high optical clarity, and remains stable no matter how it is configured. Polycarbonate plastic provides insulation in electrical and high-tech applications, protective windshields and corrective lenses, containers and bottles for fluids, durable and low cost medical equipment, and digital media in the form of CDs and DVDs and their containers. Knowing how to cut polycarbonate will let you make creative and innovative use of this handy and reliable resource.

Steps

Using a sharp utility knife to cut polycarbonate sheets

  1. Use a sharp cutting edge to cut thin polycarbonate sheeting where accuracy is not important.
    • Some polycarbonate sheeting is almost paper-thin and useful for covering and protecting gardens, for example.
  2. Use duct-tape to fix sheeting to a flat surface without stretching it because stretching it will alter the line of the cut.
  3. Measure and mark the desired cut clearly.
    • Use duct-tape to outline the desired cut.
  4. Cut along mark with a sharp utility knife.

Use heavy duty hand-shears to cut plastic along clearly marked line(s) if the plastic is stiff, brittle, but less than 0.125 inches (0.3175 cm) thick.

  1. Use shears with steady motion and pressure to cut along line until complete.
  2. Measure and mark the clear sheeting that covers the flat polycarbonate sheets to avoid scratching or damaging surfaces other than the intended cut.

Use circular saw to cut thicker polycarbonate sheets.

  1. Use fine tooth saw blade on a circular saw to cut plastic that is more than 0.125 inches (0.3175 cm) but less than 0.50 inches (1.27 cm) thick.
  2. Provide support for the plastic sheet on either side of the intended cut.
  3. Measure and mark the desired cut clearly.
  4. Use duct-tape to outline the desired cut.
  5. Immobilize the plastic with C-clamps to a flat surface.
  6. Allow the saw to cut steadily without your additional force or pressure.
  7. Complete the cut before stopping.

Use jigsaw to cut curves in polycarbonate plastic

  1. Use a metal-cutting blade in a hand-held jigsaw to cut curves or designs in plastic sheets.
  2. Secure plastic to a flat cutting surface with C-clamps.
  3. Allow the saw to cut without your force or pressure.
  4. Complete the cut before stopping.

Use a table saw to cut thicker pieces of polycarbonate, such as you might use in a window set-up

  1. Use table saw to cut through polycarbonate sheets thicker than 0.50 inches (1.27 cm).
  2. Measure and mark desired cut.
  3. Frame mark with strips of duct-tape.
  4. Mount fine toothed saw blade.
  5. Push the sheet into saw at a firm but steady pace.
    • Too much pressure or too little pressure risks cracking the plastic.
  6. Complete the cut before stopping.



Tips

  • Fine toothed saw blades should prevent rough edges, so keep blades sharp or replace them as necessary; smooth rough edges with very fine file.
  • Polycarbonate sheets usually come with a thin layer of protective paper or plastic; do not remove this protection, or you risk peripheral damage from tools and saws.
  • Dab a drop of light machine oil on the blades of the shears for an easier, smoother cut.
  • A fine toothed handsaw will cut polycarbonate sheets that are at least a quarter inch thick smoothly and easily if you don't have appropriate power tools.

Things You'll Need

  • Heavy duty hand shears
  • Tape measure or rule
  • Straight edge or square edge
  • Washable marker
  • Flat cutting surface
  • Fine-toothed circular saw blades
  • Hand-held jigsaw
  • Vertical band saw
  • Sharp utility knife
  • Fine files

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Sources and Citations

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