When you wish to make curved or rounded cuts in plastic, a jigsaw is your best bet, whether you’re working with thin or thick sheets. Ideally, you will use a sharp blade specified for use with plastics. You can also use a blade marked for wood, but it’s possible that friction from the blade will create too much heat, causing the cut plastic to melt. To prevent this from occurring, you may need to experiment with different jigsaw settings and speeds with a scrap piece of plastic. Follow the manufacturer’s instructions for how to use a jigsaw, and you’ll end up with a perfectly cut piece of plastic for your next home repair or DIY project.

Here are three different techniques for cutting plastic, depending on the thickness of the material and the desired style of cut.

Spiral Two-Flute Design: The innovative spiral two-flute design combines both up-cut and down-cut spirals, resulting in clean and precise cuts on both top and bottom surfaces of the workpiece. This unique configuration minimizes chipping and tear-out, delivering flawless results.

To make straight cuts on thicker sheets of acrylic and polycarbonate plastic (greater than ⅛ inch thick), you’ll need to use a table saw or circular saw. Use blades designed specifically to cut plastic, which are often packaged as “No Melt” blades. Ideally, the teeth of the blade should be evenly spaced, of uniform height and shape, and spaced close together. Teeth spaced wider apart may chip or crack the plastic.  Note that if you choose to use a regular blade instead of a “No Melt” blade,” creating too much heat may melt the plastic. As a precaution, pause between cuts to allow the blade to cool.

Plastic is trickier to handle for multiple reasons. For one, some types of plastic melt during the cutting process, unless you take proper precautions. For another, plastic surfaces are prone to scratches, and the edges sometimes need buffing when the project is complete.

CNC Compatibility: Engineered for compatibility with CNC machines, this router bit provides superior control and accuracy, making it indispensable for intricate designs and complex projects.

Elevate your woodworking projects to the next level with our Compression Router Bit Solid Carbide CNC Spiral Two-Flute. Meticulously engineered for precision and versatility, this router bit is designed to meet the demands of both professional woodworkers and hobbyists, ensuring impeccable results every time.

Optimal Dimensions: With a versatile 1/8" diameter and a matching 1/8" shank, this router bit offers exceptional stability and control. It's suitable for a wide range of woodworking tasks, from general routing to intricate detailing.

If you want a straight cut in a thin acrylic or polycarbonate plastic sheet (up to ⅛ inch thick), reach for a simple utility knife, then follow these steps.

Premium Solid Carbide Construction: Crafted from high-quality solid carbide, this router bit offers exceptional durability and longevity. Its robust construction ensures consistent performance over numerous woodworking projects.

There’s little debate over the proper methods to cut wood. However, cutting plastic—particularly acrylic and polycarbonate—is a whole different story.

Bob Vila is America’s Handyman. As a TV host, author, builder and historic preservationist, he has been heavily involved in construction and remodeling for the better part of a half century.

Compression Design: The compression design of this router bit ensures that the material is compressed both upward and downward during cutting, eliminating edge fraying and providing a clean finish on both entry and exit sides of the workpiece.

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A word of advice: Always take the proper precautions when cutting plastic. Secure the sheet of plastic to your workstation with a vice to ensure it won’t shift during cutting, and wear safety glasses to protect your eyes from stray pieces of acrylic or polycarbonate. Call a professional if you don’t feel comfortable taking on the project yourself, or if you don’t have the proper tools for the job.