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How to cut Lexan

Getting Started with Lexan

Before diving into the fascinating world of DIY projects involving Lexan, let’s soak in a bit of background. Lexan is a brand name for a type of polycarbonate plastic known for its incredible toughness and versatility. It’s widely used in various applications, from bulletproof windows to compact discs. Understanding the properties of Lexan is pivotal before we get into the cutting process.

Preparation is Key

First things first, preparation cannot be overlooked. Ensuring you have the right tools and a clear workspace will make the cutting process smoother and safer. You’ll need a measuring tape, a marker for precision marking, protective gear such as safety glasses and gloves, and of course, the correct cutting tool. Deciding on the right tool depends on the thickness of the Lexan sheet and the type of cut you want to achieve.

Choosing Your Tools Wisely

Choosing the right tools is like selecting the perfect ingredients for a gourmet meal—essential for an excellent outcome. For straight cuts in thin Lexan sheets, a utility knife works wonders. Just score the sheet along a straight edge and snap it over the edge of a table. For thicker sheets or more complex cuts, power tools like circular saws or jigsaws come into play. Equipping these tools with blades designed for cutting plastic will yield the best results.

The Cutting Process

Now, let’s get down to the nitty-gritty—cutting Lexan. Measure twice and cut once is the golden rule here. Use a marker to precisely mark where you want to cut. If you’re using a circular saw or jigsaw, go slow to avoid melting the Lexan from the heat generated by the blade. A simple yet crucial tip is to apply masking tape along the cut line to minimize chipping and cracking.

Post-Cutting Finishing Touches

After cutting Lexan, you might find the edges a bit rough for your liking. No worries, though. A bit of fine-grit sandpaper can smooth those out, giving your project a polished look. If you’re aiming for a glossy finish, flame polishing the edges is an option, but it requires a steady hand and safety precautions.

Advanced Techniques and Tips

If you’re feeling adventurous and looking to explore beyond straight cuts, there are advanced techniques to consider, such as thermoforming. This process involves heating the Lexan until it’s pliable and then bending it to your desired shape. While it’s a more complex technique, it opens up a myriad of creative possibilities for your projects.

In terms of tips, always remember to allow the Lexan sheet to cool down at room temperature after cutting. Rushing the cooling process can lead to warping or cracking, which can be a bummer after all your hard work. Patience is indeed a virtue when working with Lexan.

Common Mistakes to Avoid

Even the best DIYers can run into pitfalls if they’re not careful. One common mistake is cutting too fast, which, as mentioned, can melt the Lexan. Another is using dull blades, which can lead to chipping or even cracking. Ensuring your tools are in top condition before starting your project will save you a lot of headaches down the road.


1. Can Lexan be cut without power tools?

Yes, thin Lexan sheets can be scored with a utility knife and snapped along the score line for a clean cut.

2. How to prevent Lexan from cracking during cutting?

Apply masking tape along the cut line, use sharp blades, and cut slowly to reduce the risk of cracking.

3. Can you drill holes in Lexan?

Absolutely! Use drill bits designed for plastics and keep the drill speed moderate to avoid melting around the holes.

4. How do you polish rough edges after cutting Lexan?

Rough edges can be smoothed with fine-grit sandpaper, and flame polishing can give them a glossy finish.

5. Is Lexan the same as Plexiglass?

No, Lexan is a brand of polycarbonate, which is tougher and more flexible, whereas Plexiglass is a brand of acrylic, which is more brittle.

In summary, knowing how to cut Lexan properly is an indispensable skill for DIY enthusiasts. With the right preparation, tools, and techniques, you can tailor Lexan sheets to fit virtually any project, ensuring durability and versatility in your creations. Remember to prioritize safety, precision, and patience throughout the process, and you’ll be well on your way to mastering the art of cutting Lexan.

James Burnside
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