Join Date: Jan 2014
Location: South Central PA
I've cut a lot of plexy and lexan over the years. Always used a jig saw. You need one with variable speed, and use a medium coarse blade. As said above, tape it up if the barrier film is already removed. Then lay out your cut line on the tape. When you start cutting, you need to keep the plastic from bouncing, some medium density poly works well for that. If you go too fast or use too fine of a blade, the plastic will melt and try to stick to the blade, causing it to bounce with the saw strokes.
You can also just cut close to the line and do the finish work with a sander. Even when just in flat sheets, that plastic is too expensive to mis-cut.
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Last edited by Thermodyne; 11-17-2018 at 01:42 PM.