I am a DIYer needing some advice for cutting plastic sheet goods correctly.
I ‘m planning some projects that will call for the use of Plexiglass, Lexan or some polycarbonate. Most of the time when I have had to cut any of these materials I really mess up the edges and cannot seem to obtain a clean cut line.
I have good quality tools so maybe I’m not using them correctly. Should I be looking for a specific type of blade, a special saw, cutting bits? I get some nasty looking edges with tooth marks (I’m not chewing it, honest) or a melting of particles in random clumps.
I have routers, circular saws, jig saws, a band saw, table saw, mitre saw, hand saws of all types. The materials are expensive enough and I’m not looking forward to practicing with each tool. If I need to buy a special blade or bit I’m OK with that. I searched online and in Taunton for some tips & techniques but came up dry. Wrong terminology?
I am willing to learn and like to take pride in my work, but so far, I can’t say that with plastics.
Any help will be appreciated.
…The unspoken word is capital. We can invest it or we can squander it. -Mark Twain…Be kind to your children….they will choose your nursing home.…aim low boys, they’re ridin’ shetland ponies !!
Replies
I 'm planning some projects that will call for the use of Plexiglass, Lexan or some polycarbonate. Most of the time when I have had to cut any of these materials I really mess up the edges and cannot seem to obtain a clean cut line.
negative rake triple chip blade... full kerf and not the thin kerf...
here's a good one....
http://www.freudtools.com/p-41-plexiglassplasticsbr-nbsp.aspx
I have good quality tools so maybe I'm not using them correctly. Should I be looking for a specific type of blade, a special saw, cutting bits?
are or will you be using router bits???
I get some nasty looking edges with tooth marks (I'm not chewing it, honest) or a melting of particles in random clumps.
thin kerfs that chatter will do this... same for dull or a too slow (melting) or too fast of a feed rate (chipping)....
fence alignment matters also...
I have routers, circular saws, jig saws, a band saw, table saw, mitre saw, hand saws of all types.
save yur efforts and don't bother with the band or hand saws...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming
WOW!!! What a Ride!
Forget the primal scream, just ROAR!!!
Thnaks, I knew there must be something I hadn't bought yet. ;) I
hadn't planned to use a router but would if it would be easier. ...The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
if you want to cut radi and shapes...
use the router bits... the more flutes the better... slow speed....
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
score and snap works on the thin acrylics...
time to get a carbide scorer...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
Let's see.....a new saw blade, couple of new router bits and a carbide scorer.
When the DW starts to question the new stuff immediately after Christmas I can honestly say that it is all recommended by the "experts". ;0)...The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
As any woodworker/carpenter/construction guy knows. You can't use "do I need it?" as a criteria for buying a new tool. Whether or not you'll even ever use it is besides the point! For all you confused people out there, I will give you the listed reasons for buying a new tool straight from "The Man Bible" Chapter 35 Section 72 Subsection D Paragraph 23 states:
You simply buy a new tool because:
a) It's there
b) You can
c) Maybe some day “You” might just need it
I hope this has cleared up any questions any of you may have for buying new tools, and hopefully relieve some of the guilty feelings you may have about purchasing that new tool with the money you should have spent on a new dishwasher for your wife
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
excellent for polycarbonate....
http://www.cmtutensili.com/show_items.asp?pars=RB~7/8/906.191~2
good one for the acrylics....
http://www.cmtutensili.com/show_items.asp?pars=RB~190/191/192B~2
and they leave little or no chatter marks that you'll need to remove...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
now I remember...
straight bits tend to snipe and scalp plastics as where a spiral doesn't....
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
Yup, I get it. Kinda' like my jointer and planer heads. Soon to be replaced by helicals. Slice instead of chop and quieter and smoother.
Guilt? Not any more. I've EARNED them, the old fashioned way. I don't gamble, golf, ski or hunt or many other things. I like to fondle my tools ;0)
Funny you should mention the dishwasher. I just got a new one and is she ever cute. (insert rim shot here)
Kidding aside, that was a deal I struck with the DW a couple years ago when we got the new place. Any upgraded appliances, gadgets,etc. she wanted were delivered. When I need/want a tool, I do. It works great for both of us and I scored a table saw, jointer and planer in the last year and a half.....we had set aside some from the sale of our previous home so we could do this. It's been fun and I'm like a little kid in a toy store. Lots of projects going (I'm retired) and all the stuff to enjoy them with. Not all are wood munchers, either. Got some nice hand saws, planes, chisels, etc.
...The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
I see the sense in not playing golf....
but at least I hope you retained the sense to go fishing every so often...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
Fishing I'm good at......(dangling preps anyway) but catching is another story.
I seem to scare the critters away. There must be a force of sorts that travels down my arm, to the tackle and into the water warning them to stay away from this guy.
I can sit in the same boat as my son and a couple buddies and a grandson. Everyone with same or similar gear and everyone catching and getting bites except yours truly, here. Don't know why. Always been that way.
But fishing is a good excuse to get out there and I usually have my camera & a good book with me. I'm usually recruited by the others to drive the boat.
Same thing in my canoe. I've had better luck just dipping a net in than catching on traditional gear. ...The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
guess I taught ya well....
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
trap the layer of plastic between 2 pieces of wood.
Jeff
Buck Construction
Artistry In Carpentry
Pittsburgh Pa
....doh!!! The easiest isn't always obvious to me. Thanks Jeff....The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
Imerc's advice on the bits and blades still applies.
Jeff Buck Construction
Artistry In Carpentry
Pittsburgh Pa
you samwiching acrylic or polycarbinates???? Both???
thick?? thin???
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
I havent tried it, but I wonder if a small bit in a Roto-zip would work.
Edit; I would go out and try it, but its ony 8 degrees out, and garage isnt heated.
Edited 12/28/2008 9:31 am by wood4rd
too fast.....
the cutter teeth won't clear and melting becomes a major problem...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
1/8" single flute or double flute straight bit on a router will do a nice job. Dilute liquid dish soap and water to get the chips to release from the static cling afterwords.
------------------
"You cannot work hard enough to make up for a sloppy estimate."
First let me state I have never tried the following. Clean up ragged edges with a torch. Heating the edge without actually melting the piece is supposed to restore the edge to a factory cut. I have handplaned the edge a few times when needed,never tried the torch method.
Can't help on cutting plastic, I've had the same results as you.
mike
sand the edges then fume with MEC....
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
Lube with wax, grease, or spray. On the blade. On the plas. Cut slowly.
Larry b
dry lube is good too...
I'd hold the wax....
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
"Some days it's just not worth chewing through the restraints"
If you don't have a special plastic cutting table saw blade then a triple chip blade that is used to cut melamine board will also work. You will still have a rough edge that is unsuitable for display
purposes however. To achieve a polished edge you will need to cut
the plastic parts 1/8"-3/16" larger than the finished size required.
If you have access to a small table jointer, you will set the blade
height to 1/32" - 1/16" above the front table surface. Run your
plastic sheet on edge on the table and against the 90 degree fence to
help hold it square to the table face. Run all edges 1 or 2 passes
until you have reached you final size. If you are glueing these
parts together then now is the time before you polish the edges with a torch. Use a propane torch the same as you use on copper plumbing.
Use a medium flame and run it along the edge about 2" away from the plastic edge keep it slowly moving and you will see magic.
Have used a band saw on single layer sheets. Then run a sander over the edge to clean it up.
For cellular polycarb, there's a special plastics blade for circular saws. Lots of little teeth. Just clamp a straightedge and run alongside as if cutting plywood. Makes a lot of little plastic wigglies, but cuts like butter, nice and even.
Or talk to a sign company or plastics distributor. Both cut different kinds of such material all day and know the tricks.
Same here RE: Bandsaw. I just recently made a few zero clearance throat plates for the table saw. 1/4" Lexan and bandsawed them out with a 3/8th 6 tpi blade..hook, not skip.
A quick lick on the oscillating belt sander and smoothe as a baby's cheek.
Used to make clear body templates for guitars ( lay on figured wood for best grain use) and cut all of it on a bandsaw. For straight rips, the triple chip grind blade was what I'd grab, but if not a combo blade did fine. Any edge touch up was handled easily with a scraper, card style or hunk of glass.
All in all, I'd rather cut Poly carb than cast acrylic , polycarb won't shatter. Costs more, but well worth it.Spheramid Enterprises Architectural Woodworks
Repairs, Remodeling, Restorations
They kill Prophets, for Profits.
Are you cutting straight lines or curves?
Here is some stuff on EZ guide. http://eurekazone.com/gallery/the-fun-cutter
My local true value will glass and plastics on their glass cutter for a nominal fee.
Thanks for that one....I just received my EZ for Christmas and haven't had a chance to put it together/test yet....The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
You guys are the greatest. Your generosity with knowledge and experience are key. Taunton should PAY all youse guyz! ;0)
This place is what it's all about.
Many thanks to all and I'm sure I'll be trying each tip as I get into more projects. And....I get to buy another new blade, too. You know, just in case I NEED it.
I've heard about the edge treatment with the torch but haven't tried it yet. Just thinking about the quality edges I see on store displays.
...The unspoken word is capital. We can invest it or we can squander it. -Mark Twain...Be kind to your children....they will choose your nursing home....aim low boys, they're ridin' shetland ponies !!
Welcome. I use the score and snap method for a lot of plastics. Have not used my ez for plastics but should work. For those who have fought for it Freedom has a flavor the protected will never know.
Lexan won't snap, it just bends. Keep bending back and forth and it eventually warms and comes apart, but not SNAP like plexiglass.Spheramid Enterprises Architectural Woodworks
Repairs, Remodeling, Restorations
They kill Prophets, for Profits.
I use a laminate trimmer or small router with a bearing guided bit. I'll usually clamp the plastic to the bench and make the cut line even with the front edge of the bench. (the bench has a pretty straight and smooth front edge) Then run across it so that the bearing rides on the front edge of the bench. The only tricky part is when you get to the end of the cut and the waste piece is about to fall and you don't want it to chip the good part. That's when it'd be handy to have a third hand. If you needed a curved cut using this method, you'd need to make a template for the bearing to ride against.