Cutting Plexiglass With a Table Saw: Pro Tips for Smooth, Clean Edges

Wondering if you can cut plexiglass with a table saw without ending up with a mess? I’m going to share pro tips for cutting through plexiglass smoothly, ensuring clean, crisp edges every time.

QUICK ANSWER:

Yes, you can cut plexiglass with a table saw. Proper handling and the right techniques make it straightforward to yield clean, accurate cuts.

What is Plexiglass?

First, it’s not glass.  It’s actually a hard, clear acrylic, and cost-effective alternative to glass.  Acrylic is a see-through petroleum-based thermoplastic material, usually manufactured in sheets.  The technical name is Poly(methyl methacrylate). In short, it’s a plastic.

It’s lightweight and shatter-resistant and can be used in place of glass in almost all instances because it is sturdy and translucent.  Common uses include:

  • Windows
  • Lights
  • Signs
  • Screens
  • Even in viewing panels of 30-foot-deep aquariums

Plexiglass usually comes with a protective layer of paper that should be kept in place until the sheet is cut to size and finished.  Sheets should be kept uniformly supported on a flat surface until it’s time to cut.

What is Plexiglass

Types of plexiglass sheets come in two forms:

  • Cast acrylic sheets. This is what most of us know as plexiglass.  They are hard and durable and can be cut with a table saw so long as you use the correct blade and take all necessary safety precautions.
  • Extruded acrylic sheets. These sheets are not as hard and durable, have a lower melting temperature, and should be cut only with hand tools. 
  • Polycarbonate sheets. This third kind of plastic sheeting is an in-betweener.  It’s not as hard as cast acrylic sheets but has a higher melting temperature than extruded acrylic sheets.  It can be cut with a table saw but does require the correct blade and feed method through the blade.

This article will discuss various ways to cut cast acrylic sheets, primarily focusing on using your table saw.

What Is The Best Way To Cut Plexiglass On a Table Saw?

Any table saw blade will cut plexiglass.  But there are some blade considerations that have to do with the accuracy of the cut, the avoidance of chipping and splintering, and safety concerns.

The Right Table Saw Blade

Plexiglass ThicknessBlade DiameterTooth CountRecommended Blade Clearance
1/16″ – 1/8″10″ – 14″80 – 1001/8″
1/8″ – 1/2″10″ – 14″80 – 1001/4″

Selecting the appropriate blade for cutting plexiglass is crucial to the process. The thickness of your plexiglass sheet primarily dictates the type of blade you should use. For sheets ranging from 1/16th to 1/8th of an inch in thickness, it’s recommended to use a 10 to 14-inch diameter blade, with a tooth count of 80 to 100, respectively.

Blade clearance is another vital aspect to consider. A clearance of 1/8th inch above the sheet is ideal; however, for sheets between 1/8th to ½ inch thick, an ¼ inch blade clearance is recommended. While specialized plexiglass saw blades are available, any metal-cutting blade with carbide tips can also accomplish the task effectively.

Ensure your table saw is up to the task. It should be at least a 2-horsepower model, and the optimal blade speed is 3,450 RPM. This speed is not a strict requirement but is ideal for achieving the best cut. Given their hardness and high melting temperature, these specifications are particularly pertinent when working with cast acrylic sheets.

Saw Blade

Safety Concerns

Safety should always be your primary concern when working with power tools, especially when cutting materials like plexiglass that can produce harmful debris or shards.

  1. First, make sure your table saw can handle the job properly.  By this, we mean minimum horsepower and blade speed.
  2. Secondly, make sure you have chosen the right blade for the job.  We’ve already pointed this out above.  You want the right size blade, the right teeth count, and the right blade clearance.  Double-check everything.
  3. Thirdly, wear safety goggles. In fact, you should use safety goggles whenever using your table saw.  When cutting plexiglass, though, this is extra important.  The same is true for a safety mask.  Chips and dust from the plexiglass can cause serious injury to your eyes, and you do not want to inhale the dust.  

Measure the cut you wish to make, keeping in mind the thickness of the blade.  Be sure to leave the protective paper film on the sheet of plexiglass, too, as this will protect it from scratching.

When preparing to cut, ensure the sheet is tight against the table saw fence.  Be sure to keep the protective paper film side down as you run the sheet through the blade.  Use a push stick or block and move it slowly and steadily through the blade, just as you would a piece of wood.

Apply enough pressure to keep the sheet firmly against the fence as you do so.  Thinner pieces of plexiglass tend to vibrate, and you don’t want to lose contact with the fence.

Cross-cutting can be something of a challenge with plexiglass, as the corners tend to chip.  Starting the cut on one end of the sheet, flipping it over, and completing the cut from the other direction can help mitigate the chances of chipping. 

You’ve Cut The Plexiglass With Your Table Saw:  What’s Next?

The edge of your plexiglass sheet will likely be a little rough.  It might even be a bit glazed from the heat of your table saw blade.  It will need a little attention from you to finish the sheet and make it ready for your intended use.  You do want a smooth finish on the cut edge.

Choose 120-grit or 180-grit waterproof sandpaper for the job.  Attach it to a sanding block, and use it lightly on the cut edge.  Graduate to finer grit sandpaper, up to 600 grit, and you’ll have a smooth finish. Alternatively, you could use a buffing pad attached to a power drill for an even smoother finish.

However, remember that a polished plexiglass edge can not be glued, depending on your project.  If gluing will be a part of your project, skip the polishing.

Do You Need To Use a Table Saw to Cut Plexiglass?

No, you don’t have to use your table saw.  There are other methods of cutting a plexiglass sheet, and it depends on the thickness of the sheet.

For instance, with a thin sheet, 1/8th of an inch, you can use a plexiglass knife or even a utility knife.  Run the knife along a straight edge at your measurement a few times, going slightly deeper with each pass, and then snap the sheet where you’ve scored it.

You can also use a jigsaw to cut your sheet.  There are plexiglass blades for your jigsaw that will do a very nice job on plexiglass sheets of any thickness.

Thirdly, you can use your circular saw.  Use a plexiglass blade for the purpose on sheets of any thickness.  The cut will be similar to that from your table saw.

In each instance, the finishing process is the same – – fine-grit sanding paper on a sanding block to make it smooth.

Special blades or blade requirements, a few extra steps for a clean and straight cut, and safety considerations all come into play when using your table saw to cut plexiglass.  The finishing steps are no different, though, with a piece of wood or metal.

The answer to the question is yes, you can use your table saw to cut plexiglass.  Follow these steps, and refer to the videos we’ve offered to illustrate, and you’ll do just fine.

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