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Lets Settle this now, Plexi Cutting

S

SquiDDy

Limp Gawd
Joined
Feb 4, 2003
Messages
336
what is the best way to cut plexy in non, square shapes???


everytime i try with my saws, it puts big cracks in it, and when ever i try to score it, then snap it, it is always wavy shaped and not very precise

so, how do you guys get such good cuts on the plexi??
 
Home Depot :)

They have a Plexi-Cutting device.

For round shapes, I guess you could use a dremel. It doesn't crack the plastic. Or a drill saw.

Anything that doesn't have a circular motion applying force DOWN onto the plastic should work. Rotation should go with the plastic (like a drill bit).

When using a dremel, it might be wise to run water onto the bit (BUT NOT ONTO THE DREMEL!) if you want a clean cut, as the bit gets incredibly hot and begins to melt the plastic.
 
If you've got access to one, a router should work well.

Also, for straight lines a table saw is fantastic.
 
Just say no!

...to acrylic. I love my polycarb, so much easier to work with, and a heck of a lot tougher, too. (Think SWAT team shield)
 
so a dremel with the atachment for cutthing things


like is on the end of this

sj330s07.jpg


wiht the proper bit should do the job for curves/straight lines?
 
Is this topic serious?

Non-straight cuts? Use the proper tool for the job -
Jigsaw with the proper tooth-type / -count blade.
That, or a bandsaw.

The pictured Dremel cutting tool is good for rough cuts in plex or drywall, but particularly in plex the rotation of the bit is going to make it VERY difficult to accurately control.

Jigsaw.
 
Straight cuts = Jig Saw/Band Saw/Scroll Saw with proper blades
Circular = I would go dremel with a wheel. If your careful and go slow you can do it(some plexi melts as its being cut, usually comes right off though)
 
Originally posted by phasmatis_nox
Just say no!

...to acrylic. I love my polycarb, so much easier to work with, and a heck of a lot tougher, too. (Think SWAT team shield)
Click to expand...

Link to buy polycarb
And dont give me that tap-plastics shit. There are none in georgia and their website doesn't list acrylic or other sheets
 
Originally posted by Ruffy
Link to buy polycarb
And dont give me that tap-plastics shit. There are none in georgia and their website doesn't list acrylic or other sheets
Click to expand...
Amen brother Im sick of hearing about tab-crap too ;) :p
 
ah yes...lexan...
my dad worked for a plastics company and all of the shields were made of lexan...so guess where my side window came from :D

it's tough as hell and a b!tch to drill, cut, etc...but it's damn near indestructable...
 
In high school we used a band saw for cutting.
 
Scroll saw, definatly

you can cut curves as small as .2" diameter, and i have yet to break or crack a piece.
 
Originally posted by fubar569
it's tough as hell and a b!tch to drill, cut, etc...but it's damn near indestructable...
Click to expand...

Man, what kind of dull tools were you using? Cuts like butter for me.
 
Originally posted by fubar569
ah yes...lexan...
my dad worked for a plastics company and all of the shields were made of lexan...so guess where my side window came from :D

it's tough as hell and a b!tch to drill, cut, etc...but it's damn near indestructable...
Click to expand...


i love lexan it doesn't crack you can basically bend it in 2 and it will not snap.
 
Originally posted by phasmatis_nox
No more easily than acrylic, less I'd say. All hail lexan.
Click to expand...


Polycarbonate scratches immensly easier than standard acrylic
 
Originally posted by Ruffy
Straight cuts = Jig Saw/Band Saw/Scroll Saw with proper blades
Click to expand...
huh? do you not know that those saws are especially suited to cutting curves??
 
Originally posted by rayra
huh? do you not know that those saws are especially suited to cutting curves??
Click to expand...

yes but I wouldn't try cutting acrylic with a scroll saw. Band/Jig with small blades yes.
 
so i want to use lexan it sounds like, and a jig saw with a fine tooth blade ??

i just purchased a 80mm hole bit for my drill, took it to my window, and all of the plexi cracked :(

looks like i will be replacing that window, its ok though, i was going to anyways

so you guys are absolutley positive i should use lexan??

and when im cutting it, how should i hold it down?
 
ok noob question.


So what are the differences between plexiglass, acrylic and polycarbonate? ie strength, bending, cutting, price, etc
 
my manager at my work says that the best way to cut acrylic is make sure that's very solidly held down and unmovable and to work slowly. also when cutting to score it many times to wear through the acrylic.
 
Believe it or not, Dish washing soap is good "cutting oil" for plexi.

IF you use the little dremel adapter thing, it might be a good idea to make a guide out of wood to clamp on to your work. if you were making a circle you could cut a circle which is.

radius of circle + radius of dremel adapter thingy - radius of bit.

I had good luck using a Fly cutter with plexi

heres what a fly cutter is
http://www.cumpiano.com/Home/Classes/Rosette/inlay.htm

this hole In 1/4 inch plexi was done with fly cutter. it has not been sanded or anything since it was cut.

flycutter.jpg


of course you need a Drill press to do it on, but i found that cheapo fly cutter at home depot for $20 canadian or something. it takes standard 1/4 lathe bits so you can sharpen/ replace them if they get burnt.
 
hehe man nothing beats laser cutting. alot of plastic stores offerit. its expensive but the cuts are perfect. You give them an illustrator layout with dimensions and they will do it ffor ya!
 
Lexan is just soo much easier to work with. It doesn't crack unless you're using a jackhammer or something. It's the stuff bulletproof 'glass' is made from. Still not to hard to cut though- I've used a coping saw on it before, with ease.
 
ok, well i went out and bought some lexan today to replace all my windows in my comp, all 3, and well..

it worked perfect, cut great, although i did crack my mainwindow, but that was because i kinda sorta lost control of the saw, did somthing ishouldnt have, but anyways, cut perftec,t drilled 4 different fan holes with out any problems,

this is deff the way to go as far as windows are concerned

maybee it should be added to the faq in more detail?
 
Originally posted by DeFex
Believe it or not, Dish washing soap is good "cutting oil" for plexi.

IF you use the little dremel adapter thing, it might be a good idea to make a guide out of wood to clamp on to your work. if you were making a circle you could cut a circle which is.

radius of circle + radius of dremel adapter thingy - radius of bit.

I had good luck using a Fly cutter with plexi

heres what a fly cutter is
http://www.cumpiano.com/Home/Classes/Rosette/inlay.htm

this hole In 1/4 inch plexi was done with fly cutter. it has not been sanded or anything since it was cut.

http://www.neutron7.com/images/flycutter.jpg

of course you need a Drill press to do it on, but i found that cheapo fly cutter at home depot for $20 canadian or something. it takes standard 1/4 lathe bits so you can sharpen/ replace them if they get burnt.
Click to expand...

Whoa that looks MUCH easier for cutting nice holes in plexi than anything Ive tried. Also allows multiple size holes to be cut with one item insted of buying 3-4 hole saws. What diameter holes can those cut?

*Runs off to find a place to order one online*
 
Originally posted by Da Fan Man
Whoa that looks MUCH easier for cutting nice holes in plexi than anything Ive tried. Also allows multiple size holes to be cut with one item insted of buying 3-4 hole saws. What diameter holes can those cut?

*Runs off to find a place to order one online*
Click to expand...

I have one, things to keep in mind:
--Toss the cutter that comes with it. Buy a new one from MSCdirect.com(You can get the tool itself there too)
--Most ones you'll encounter will have one arm- if the tool is not perfectly parallel to the workpeice, everything will go to hell. Don't even think about it without a drill press.
--I tried to use one to cut into a PSU cover, and the circumfrence of the hole intersected with some existing vents. BAD. Don't even think about it. No way. If there's anything at all in the path of this thing that could cause the slightest uneveness- move the hole, or make it smaller.



ok, well i went out and bought some lexan today to replace all my windows in my comp, all 3, and well..
it worked perfect, cut great, although i did crack my mainwindow, but that was because i kinda sorta lost control of the saw, did somthing ishouldnt have, but anyways, cut perftec,t drilled 4 different fan holes with out any problems,

this is deff the way to go as far as windows are concerned

maybee it should be added to the faq in more detail?
Click to expand...

You have seen the light! Polycarb = teh awesomeness.
 
Originally posted by phasmatis_nox
I have one, things to keep in mind:
--Toss the cutter that comes with it. Buy a new one from MSCdirect.com(You can get the tool itself there too)
--Most ones you'll encounter will have one arm- if the tool is not perfectly parallel to the workpeice, everything will go to hell. Don't even think about it without a drill press.
--I tried to use one to cut into a PSU cover, and the circumfrence of the hole intersected with some existing vents. BAD. Don't even think about it. No way. If there's anything at all in the path of this thing that could cause the slightest uneveness- move the hole, or make it smaller.

You have seen the light! Polycarb = teh awesomeness.
Click to expand...

yeah i ought to have mentioned that :). BTW most of the fly cutters i have seen (also called "circle cutters") take standard 1/4 inch lathe bits which makes them not too hard to find.

and the bit that comes with it is crap, no good for metal at all.
 
Originally posted by DeFex
yeah i ought to have mentioned that :). BTW most of the fly cutters i have seen (also called "circle cutters") take standard 1/4 inch lathe bits which makes them not too hard to find.

and the bit that comes with it is crap, no good for metal at all.
Click to expand...


Alright, those looking for one, McMaster part number 8830A13 is what I have, but it's cutter size is not standard. So if you want to do anything other than plastic, get: 3082A2. I really do reccomend replacing the bit regardless, so get the second one.

(BTW, if anybody gets the second one, I have 2 replacement bits that will fit that one, but not mine.)

As far as other replacement bits go: For the second McMaster Item number, order: 02622165 for cutting plastic, and/or 02632164 for cutting metal and plastic. If you are going to be doing some major heavy duty work on real thick and tough steel, get 72661168. All these number match MSCdirect. (.com)


Hope somebody gets some good info out of this post.

BTW- McMaster calls them "Adjustable holesaws"
 
Basicly just thinking of ordering one to cut a hole or two in some lexan. Would the cheaper one from mcmaster work without replacement blades? Ill be cutting at most 3 holes, probably only two.

Edit: I do have access to a drill press, so if the press itself is level and I insure the workpiece is level I should be good to go?

Thanks for the great information!
-Matt :cool:
 
Originally posted by The Other
Lexan anyone?
Click to expand...

Lexan is a brand name :p
Seriously though if you dont mind paying the extra poly carb is the way to go the stuff is bullet proof. But it does scratch a bit easyer but on the pluss side easyer to get the scratches out as well.
 
If you have access to one then there is nothing better than a lasercutter. My school has one and I have had a number of pieces cut out with it. Added bonus that the cuts are always perfectly precise. I'll post up some pics of stuff I have cut out when I get back to school tomorrow.
 
Originally posted by Da Fan Man
Basicly just thinking of ordering one to cut a hole or two in some lexan. Would the cheaper one from mcmaster work without replacement blades? Ill be cutting at most 3 holes, probably only two.

Edit: I do have access to a drill press, so if the press itself is level and I insure the workpiece is level I should be good to go?

Thanks for the great information!
-Matt :cool:
Click to expand...


Sure. Use dish soap for lubricant.

Yes.

You're welcome.
 
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