Plexiglass is a type of plastic acrylic, which is used as an ideal substitute for glass in furniture, craft items, picture frames and greenhouses. As compared to glass, it is lightweight, more durable, does not break easily, is resistant to heat, and is cheaper. It is available in different designs and forms, like transparent, translucent and opaque. However, there are some drawbacks associated with this material. It can chip, smear, melt or break, if it is not cut carefully. It is also prone to scratches. The tools for cutting plexiglass may differ with the thickness of the material, the purpose of cutting it and the frequency of cutting. While it can be cut with simple tools, some situations require specialized tools.
What is Plexiglass Made Of
It is a synthetic polymer of methyl methacrylate, i.e. polymethyl methacrylate, which is commonly known as acrylic glass, acrylic, perspex, or plexiglass. Polymethyl methacrylate (PPMA) was developed during the late half of 1920s and was patented by the German chemist Otto Röhm in 1933. The commercial production of this material was started in 1936. In order to manufacture one kilogram of PPMA, around two kilograms of petroleum is required. It is generally produced by methods like emulsion polymerization, solution polymerization, and bulk polymerization.
How to Cut Plexiglass
Various tools are used for cutting plexiglass as per its use and the thickness of material. This material can be cut by sawing or routing with power equipment saws. It can also be cut by scribing and breaking. While scribing is more appropriate for straight cuts in thin pieces (less than 0.236 inches in thickness), sawing and routing can be used for making straight as well as curved cuts in plexiglass of any thickness. If you want to cut curves, plexiglass that is more than 1/8 inch in thickness should be used, and the blade used for cutting should be fine toothed. In case of sawing, circular blade saws are used for making straight cuts, and scroll and saber saws are used for rough cutting of small-radius curves in thin plexiglass. Large-radius curves (rough cutting) are made by band saws, which are also used for making rough straight cuts in thicker varieties. Cutting and trimming of edges are done with the help of routers and woodworking shapers. Routers is usually used for trimming purposes.
With Dremels
Dremels allow the user to cut a wide range of materials at very high cutting speeds. The cuts made by this tool are found to be of high quality with good finish. By using a dremel, you can cut in a straight line, in curves, or any other shape you desire. Once you make the necessary marks in the plexiglass through which you have to make cuts, insert a 561 multipurpose cutting bit into the tool. If you have to make straight cuts, you have to clamp it to a straightedge, so that it does not move while cutting. Now, turn on the tool on to 6 or 8 and start the cutting process. It is always better to cut plexiglass with a 45 degree angle, as you begin the process. Once the cutting is over, remove the cutting bit and waste materials from the tool, after unplugging it.
With a Table Saw
You have to start with marking the cuts on the plexiglass sheet. In case of thin glass, use a saw blade with more teeth, so as to avoid chipping of the material. The selection of blades depend upon the material and the shape of cutting. You will develop a fair idea about the use of different blades, on a trial and error basis. Once the cutting is over, use sandpaper to smooth the edges of the cuts.
This is only a brief overview about cutting plexiglass with the help of different tools. But make sure of the safety measures, like using safety glasses (goggles) to protect your eyes from flying chips. Plexiglass, being a combustible material, fire safety measures are also necessary.
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