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Misc Forums => How To Section => Topic started by: MRK on May 06, 2016, 11:05:42 AM

Title: Best tools for cutting polycarbonate sheets?
Post by: MRK on May 06, 2016, 11:05:42 AM
I'm going to "fabricate" a window made out of 1/8" polycarbonate sheet. I was going to use a jigsaw on a slow oscillation with a fine blade to rough it out and then a palm sander to finish it.
What say you??
Thanx in advance, Mike
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: RichFox on May 06, 2016, 11:07:37 AM
Pretty much what I did. Didn't really worry about blade speed on my jig saw.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: Eddieschopshop on May 06, 2016, 11:21:21 AM
Yup Jigsaw will go through like butter,  not as brittle as plexi so won't crack or blow out from the cutting as easy
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: Bob Drury on May 06, 2016, 11:25:36 AM
  As for drilling holes (as if You asked) I know that TAP Plastics has specialty drill  bits for sale.  Any one out there had good or bad luck drilling holes?
                                                                      Thanx, Bob
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: jdincau on May 06, 2016, 11:31:35 AM
Leave enough excess with the saw so you can sand the edge smooth. The smoother the better, it will help prevent crazing later (yes crazing with Lexan). Drill the holes oversize to prevent stress cracks.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: noboD on May 06, 2016, 12:21:20 PM
For straight cuts use a sheet metal sheer. It can also be bent in a brake.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: Speed Limit 1000 on May 06, 2016, 12:23:52 PM
Trepan drill bits drill clean small holes. Unibits are good for larger holes. Baby oil is a good lube. Run the drill in slower speeds to keep from melting the plastic, a little practice drilling on scrap will help.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: RichFox on May 06, 2016, 04:36:23 PM
I use a center drill. Plexy or Lexan works great. As long as that is the size you want.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: hotrod on May 06, 2016, 04:59:37 PM
Here is a video of a guy doing an 1/8 inch lexan windshield for a plane.
Guy does the major cuts with tin snips on lexan this thick, smooths edges of cut with a carpenters block plane and final cleanup of the edge with sand paper.
Makes some interesting observations about heat forming it with a heat gun as well.

Just a bit of not work safe "tradesman" language.

https://www.youtube.com/watch?v=z8TjOGy0b-U

Cold bending with a sheet metal break

https://www.youtube.com/watch?v=sNWqbAz6Lww

Hot bending with heat gun

https://www.youtube.com/watch?v=6ik-wqRNFSE


Interesting vacuum forming setup (example using styrene plastic)
https://www.youtube.com/watch?v=maH5Ech0wK8

Title: Re:
Post by: t-rod on May 06, 2016, 08:29:52 PM
I happen to work in a plastic fab shop. I imagine no one needs to vacuum form polycarbonate for car windows, but polycarb doesn't form as easily as styrene. Jigsaws and sheet metal shears work great on polycarb.

Sent from my SM-G386T using Tapatalk

Title: Re: Best tools for cutting polycarbonate sheets?
Post by: MRK on May 09, 2016, 11:30:29 AM
Great stuff. I'm inspired! Thanx to everyone who posted. :cheers:
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: wobblywalrus on May 11, 2016, 01:13:54 AM
A steel burr in a Dremel tool is what I use for drilling and cutting thinner and smaller pieces like bike windshields. 
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: floydjer on May 13, 2016, 11:23:26 AM
Single flute bit in a router makes short work of it as well.
Title: Re: Best tools for cutting polycarbonate sheets?
Post by: Speed Limit 1000 on May 13, 2016, 09:35:05 PM
Single flute bit in a router makes short work of it as well.


 :cheers: