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

The best tool for cutting thin plastic (¼ inches or less) is a utility knife. Examples of thin plastic are plastic banding, plastic packaging, and plastic sheets.

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Cutting brittle hard plastic with the wrong tool can result in a fractured or broken edge. Using a saw or a piece of string depends on the size of the cut, cut direction, and the level of precision.

Since not all types of plastic that you use will be the same, we recommend trying different tools. Make a small cut with each tool to see which one gives you the best result. You may need to combine multiple tools to get it right.

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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.

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If you’ve cut plastic before, you know that finding the best tool for cutting plastic can be challenging. Cutting plastic is not just about getting the job done. You need to find the right tool, so you can cut safely and get a good clean cut.

If you prefer a traditional handle, the 10490 Manual Metal-Handle Utility Knife comes with a thinner 10524 Utility Blade and has optional 10525 and 10523 blades.

The best tool for cutting hard plastic is a saw or a piece of string. Hard plastic can be thin or thick but differs from the rest because of its brittleness. Hard plastic examples include plastic pegs and plastic toys.

To cut thick plastic, you'll need a fine-toothed saw, jigsaw, or table saw, since plastic can be tough to cut through. Start by clamping it to a workbench or holding it firmly so it doesn’t move. Then, use a fine-toothed saw to make the cut. Use the full length of the blade and move the saw in quick, smooth motions. If you have trouble, try drilling small holes along the line you want to cut to weaken the plastic first. Alternatively, use a jigsaw to cut through the plastic. You can also use a table saw, but make sure you use a non-melt blade so the heat of the saw doesn’t melt your plastic For more tips, including how to slice through plastic with a piece of string, read on!

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The best tool for cutting thick plastic (thicker than ¼ inches) is a saw. Thick plastic examples are plastic piping, plastic skirting, and Perspex sheeting. The three best types of saws for cutting thick plastic are a fine-toothed saw, a jigsaw, and a table saw.

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

We also recommend using one of our pointed tip blades like the 10528 Pointed-tip Utility Knife Blade if you need to initiate your cut with a puncture, such as in the middle of a sheet of plastic.

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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.

*The RPM and Chip Load that automatically populates in this calculator are the factory suggested parameters for running the desired tool. Altering the Chip Load or RPM settings in any way without prior written approval from an authorized agent of CGC/Gorilla Mill will void any guarantee or warranty nor will CGC/Gorilla Mill or its agents be liable for any consequential damages due to said alteration.

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.

No matter what tool you end up using, always remember that the best tool for cutting plastic will give you great cutting results and keep you safe.

A utility knife is the best option because it provides a good grip and control. A utility knife works in a similar way to scoring glass. It creates a shallow cut in the plastic, which makes it easy to either break the plastic or cut through completely.

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.

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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.

Using the wrong tool can result in a poor cut, and can also be dangerous. Before we get into the best tool for cutting plastic, here are some of the worst tools for cutting plastic.

Slice® manufactures some of the safest utility knives on the market. For cutting through thin plastic, we recommend our range of utility knives, including the 10558 Smart-Retracting Utility Knife, the 10554 Auto-Retractable Utility Knife, or the 10550 Manual Utility Knife.