Googling seems to bring up alot of different ways to cut lexan. non of these agree with each other.

Has anyone done this. I need to cut from a sheet so i was thinking jigsaw but i am worrid that this might melt the plastic

Any pointers from people who have already done this??

Thanks in advance

Rupert

i used a jig saw but there again i'm the same guy that used a normal grinder to cut an ally sheet .

you can cut polycarb with a jigsaw, make sure you use a plastic cutting blade with small teeth. You may fine the sheet weld itself back together after you have cut it. May wanna try some tin snips.

Allan

I would use tin snips but it is 6mm thick. Forgot to say that! Do i need a jigsaw with a variable speed?

For persepex you need paper/plastic sheet on the top and bottom, I think (memory may not be quite correct!) this stops the plastic melting and welding behind the cut. Maybe the same for lexan? As said use a fine blade.

Check it works on a peace that dose'nt matter first!

Dan

Put masking tape along the cut line (top & bottom) and use a fine jigsaw and take it very slow - does the trick for me

great thanks!! Will do that!

just one more question then. Should i take the protective plastic off and then put masking tape on??

Thanks

Rupert

I use lexan for safety glass on the special equipment we are building (professional). When we cut Lexan leave the masking foil on the lexan when cutting! Masking tape is only to protect the lexan for scratching and to mark the dimentions.

We use a normal jigsaw, slow speed, jigsaw origional used to cut wood.

Regards, JP

I used a normal reasonably rough wood blade in a jigsaw with no issue at all.

Was a 2 speed jigsaw on slower setting, no melting, no problems.

It was 6mm Perspex which I can't see being that much different to lexan.

I too will need to cut some lexan in the near future. My thought was to use a bandsaw with a metal cutting blade. Will this work? After the plastic is cut, is a long file used to smooth the edges? Seems like it would still be rough. Do you typically sand it down through the grits and follow up with a polish?

Whew! Sorry for all the questions...

--Chris

My jig saw runs so slow you can count the strokes on the first speed. I used a medium wood blade as the metal blades left a lot of debris that melted back together behind the cut. I cleaned the edge with emery cloth rubbed along not across

You can even cut this stuff with a circular saw with small teeth.

But personally I would go for a jigsaw with a normal wood blade. Use coolant if you need to stop the plastic trying to weld itself back together.

Lexan (polycarbonate) is very durable so don't worry too much about breaking it. Perspex (acrylic) is a different animal and care needs to be taken cutting it.

Wow! Thanks for the help! Will be cutting tonight so finggers crossed

Rupert

How did this turn out? Month's afterward, I finally ordered my lexan

--Chris