How to Cut Plexiglass in 4 Steps or Less

Taking on a DIY project that requires cutting plexiglass, but not quite sure where to start? Whether you’re making a custom table top, picture frame, window, or dry erase board, cutting plexiglass doesn’t have to be complicated. Use this guide to learn how to cut plexiglass with tools you have at home.

How to Cut Plexiglass with a Saw (Hand Saw, Table Saw, Jigsaw, Etc.)

Cutting plexiglass with a saw is a very similar process to cutting it with a knife—the prep and setup stay the same; only the cutting step is different. 

The biggest benefit to cutting plexiglass with a saw rather than a knife is that you can get a more precise cut with less effort and less time. 

Before getting started, it’s important to make sure you’re using an uncoated fine-tooth saw blade. This method will create a lot of dust, so consider using eyewear and a mask to protect yourself from airborne debris. 

1. Mark a Cutting Line

Start by laying the plexiglass sheet on a flat and stable surface—we recommend a sawhorse or two tables. Using a spring or C clamp, secure the plexiglass in place so it doesn’t move while you mark and cut it. Then, mark the line you want to cut using a dry erase marker and a ruler. 

2. Cut Carefully

Start from the edge of the plexiglass and use your saw along your marked line to cut slowly and precisely across the sheet. 

If you’re cutting a shape toward the center of the plexiglass, start by using a drill and bit to create a hole along the cutting line. From there, place the saw blade into the hole you just created, and slowly guide the saw along the outline until your desired shape has been cut out.  

3. Sand the Edges 

Finish the cut by wet sanding the edges with coarse-grit paper. For final touches, use a super-fine grit paper. Remember—be careful to not create too much friction. Heat can warp plexiglass, making it unusable. 

Plexiglass: What You Need to Know

Before getting started, it’s important to learn a little bit about plexiglass to avoid unwanted scratches and braking. 

• Plexiglass scratches easily. It doesn’t take much for plexiglass to scratch, so be careful to keep cutting tools away from the surface. 

• Plexiglass has a layer of film. Since plexiglass is so prone to scratching, it most often comes with a layer of protective film. Wait until you’re finished cutting to remove it.

• Plexiglass is shatterproof. Unlike traditional glass, plexiglass is shatterproof, so you don’t have to worry about it breaking into sharp pieces while working with it.