It's a type of plastic that is used to make or modify window panes.It's fairly easy to cut, and comes in sheets.Thinner sheets of plastic can be snapped with a knife.Straight cuts can be made using a circular saw.You can use a jigsaw if you want to cut angles or shapes.When working with power tools, make sure to wear protective eyewear, gloves, and earmuffs.
Step 1: The edge of the flat surface should be covered with a polycarbonate sheet.
Put your plastic on a table or saw station.Any surface can work if it is stable and has an edge.To score and snap an edge, you need to be able to hang a piece of plastic off of the edge.Tables in the corner are a bad choice for snapping.You can snap it if it's thinner than 1 in.
Step 2: Put on gloves and glasses to protect yourself.
There may be a few small pieces of plastic that fly off of the line that you cut when you snap the polycarbonate.To protect your eyes and hands, wear goggles and gloves.
Step 3: The cut line should be marked with a straight edge and marker.
To keep your line straight, use a straight edge to measure any cuts you want to make.You should hold the straight edge against the line that you plan on cutting.The junction is where the straight edge and plastic meet.To mark your cut, run your marker along the line.You can mark your cut with a grease pencil, permanent marker, or dry erase marker.
Step 4: Place the cutting line within 3–4 in of the edge and secure it with the clamps.
The edge of the work surface is near the cutting line.C-clamps are placed around the edge of the table where the plastic meets it.Pull the Trigger on the handle or twist the bolt on top of the C-clamps to tighten it.A heavy object can be placed in the center of the plastic sheet.
Step 5: Score the line with a knife.
Use the cutting line to line up your straight edge.The utility knife should be held against the straight edge of your line.Press down with moderate pressure and slide your knife at a 45 degree angle along the cutting line.Push it down the entire length of your cutting line.You do not need to press hard.The aim is to cut halfway into the plastic sheet and then snap the section off after you weaken it.
Step 6: Cut the other side of the sheet if necessary.
After you score the cutting line, you should be able to open your sheet.Press on the edge of the table to see if it moves.If it doesn't give, flip the sheet over and re-lamp it.Cut the line from the other side the same way you cut the first side.If your sheet is thin, you don't need to do this.
Step 7: Attach the sheet to the edge so that the line hangs from it.
If you apply pressure to the edge, the sheet will move if you slide it out.The cutting line should be floating out past the table if the clamps are tight.
Step 8: Press down quickly to snap the excess polycarbonate off.
Press down on the center of the sheet with your nondominant hand.Keep the sheet of plastic still and hold the excess section of your dominant hand.Press down with firm pressure if you lift it up a little bit.The side that you are pressing on should stop snapping.The easiest way to create a clean line is by scoring.
Step 9: You can set up a work station or saw horses with your polycarbonate.
You can put plastic on your work station.There will be plastic dust from the cutting, so set your station up in aventilated area.If you have a heavy sheet of plastic, you don't need to attach it to the horses.If you want to keep it secured or hold it still, you can use some C-clamps.
Step 10: Use a marker to mark the line that you want to cut.
Straight cuts are easier to cut with a circular saw than at a slight angle.Use a ruler or yardstick as a straight edge to mark your cutting line with a grease marker, permanent marker or dry erase marker.If you want to cut multiple lines, mark all of them.The best way to cut curved shapes is with a jigsaw.You can't score and snap it if it's thicker than 1 in.These thicker plastic can be cut with a circular saw.
Step 11: Attach a blade for cutting plastic to the saw.
Remove the nut from the center of your circular saw.Put on a pair of thick gloves and carefully remove your current blade from the bolt in the center.The blade is designed for cutting plastic.The center bolt needs to be tightened.If it is designed to cut plastic, it will say "plastic" on the side of the blade.If you can, use a blade with at least 3 teeth for every 1 in of the saw.As long as the blade spins fast, it will work.
Step 12: Gloves, earmuffs, and protective eyewear are required.
If you don't take proper precautions, it can be dangerous to cut polycarbonate with a circular saw.You should wear goggles to protect your eyes.If you have sensitive hearing, put on a pair of gloves and earmuffs.
Step 13: Line the saw base plate with the straight edge.
The guide line on your saw's base plate is a metal plate.The guide line is on the front of the circular saw.Go against the edge of the base plate with your straight edge.Hold the saw's handle with your dominant hand and then move your other hand aside and brace the straight edge to keep it still.There is no need to use a straight edge if you have a steady hand.Since the blade pulls the device forward, circular saws are easy to guide.You can use both hands to operate the circular saw if you want to.
Step 14: To start cutting, pull the trigger on your saw.
If you want to give the blade time to get up to speed, pull the Trigger on the saw.The teeth on your saw blade need to catch on the plastic.The saw is going to pull itself forward.There is no need to apply a lot of pressure to the circular saw.Allow the saw to pull itself so that you don't add any unnecessary tension.Release the Trigger if you feel the saw buckle.Pull it back a bit.Try to cut the line a second time.
Step 15: All the way through the end of the cut is how to slide the saw.
Guide the saw through the entire cut.To follow the saw, slide your free hand up the straight edge.The base plate should be slid against the straight edge until you go all the way through the line.The piece should fall to the floor.The saw should be unplugged when you're done.If your sheet is large, you can put the saw back up on the opposite side of the cutting line and make 2 cuts in the middle.If you want to smooth the edges out, you can use a sanding brick.
Step 16: Attach the blade to the jigsaw.
There are different blades for different materials in a jigsaw.You can get a blade designed for cutting plastic if you read the label on the blade's packaging.The safety is on the side of the jigsaw.Take the blade out and put it in.The base of the saw should be locked in place.The cut to the plastic may melt if you use a blade designed for wood.The best way to cut at an angle is to use the jigsaw, since it cuts by moving a blade up and down.
Step 17: You can put it on a work station or seen horses.
You should take your materials to aventilated and safe area.You can put your sheet on a table or horses.There is a safe area away from the area you are cutting.
Step 18: Wear gloves and protective eyewear.
There will be small pieces of plastic when you see it.Wear goggles and gloves to protect your eyes and hands.Wear earmuffs if you have sensitive hearing.
Step 19: Attach your cutting lines with grease.
To determine where you are going to cut, draw each cut out on your plastic with a grease marker.If you want to make a perfectly straight line, use a straight edge and drag your marker at a 45 degree angle against it.The base plate can be guided freely.
Step 20: The base plate should be lined up with the edge you plan on cutting.
The edge of your base plate is where you are going to start cutting.The guide line on the front of the base plate tells you where the blade is.The guide line needs to align with the section you want to cut.
Step 21: Pull the trigger on the jigsaw with your free hand.
You need to keep the plastic still while you cut because the blade of the jigsaw will move up and down.The edge of the plastic is 2–3 ft away from the spot that you are cutting with yourdominant hand.Take a few seconds to let the blade get up to speed.If you want to move the plastic at the same time that you rotation the jigsaw, you will have an easier time.
Step 22: The excess plastic can fall if the jigsaw is moved through each line.
You should keep a firm grip on your jigsaw.If you want to cut across the line, you have to slide the jigsaw forward.While using your nondominant hand, turn the plastic to adjust the angle of the cut.If you are not turning your plastic to help cut it, use your free hand to hold it in place.The saw should be unplugged when you're done.The jigsaw requires more pressure than a circular saw.