Cutting Plexiglass with a Table Saw — A Complete How-to Guide

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Cutting plexiglass on my own felt daunting at first. It’s one of those materials that can easily chip or crack if not handled just right. But don’t worry! I’ve got you covered. Let’s dive into a simple guide on masterfully using a table saw on plexiglass. Together, we’ll make it smooth and hassle-free.

About Plexiglass

Plexiglass, also known as acrylic, is a more affordable alternative to glass. Because it’s lightweight, shatterproof, and relatively durable, it’s often used in industrial, commercial, and residential projects. In fact, when tested against thicker glass, plexiglass wins in terms of impact resistance.

However, you should know that plexiglass melts and scratches easily. When cutting it using a table saw, you should follow the necessary safety precautions to avoid damaging the material.

How to Cut Plexiglass With a Table Saw

Step 1: Gather Your Equipment

Before anything else, be sure to have everything you need in your work area. Besides your plexiglass sheet and your table saw, you should have a tape measure (or any measurement tool), a permanent marker (or any writing tool), sandpaper, and safety goggles.

safety gloves, measuring and cutting tools

If you plan to polish your plexiglass after cutting, bring out an electric drill and a buffing pad as well.

(If you are looking for the right tool for this project, you can consider the list of powerful Delta table saws here)

Step 2: Measure the Thickness of the Plexiglass

Use your tape measure to check the thickness of the plexiglass [1]. If the material is less than 1/4 inch thick, you should use a utility knife instead to avoid chipping or melting from the residual heat of the table saw.

If your plexiglass is thicker than 1/4 of an inch, go ahead to the next step.

Step 3: Choose the Right Saw Blade

Because plexiglass comes in soft and hard varieties, you have to adjust your saw blade based on the material you’re working with.

For harder plexiglass, pick a blade with more teeth—this will ensure a smooth and clean cut with minimal chipping. On the other hand, a blade with fewer teeth will work better on soft plexiglass. Because this is more prone to melting, it’s ideal to lessen heat and friction produced during the process.

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Generally, though, plastic substances require blades with 60 to 80 teeth—less than other materials—to avoid burning. Evenly spaced teeth with no rake will also ensure quick and straight cuts.

For optimal results, pick blades made from high-quality carbide. These models are pricier, but they do a much more impressive job.

Step 4: Measure the Size of the Cut

Next, measure out the size you want and mark it clearly on the plexiglass. Since your table saw will have a fence to hold the glass in place, account for any extra space it may take up. If you’re unsure, it’s a good idea to leave some allowance, as you could end up with a smaller piece than intended.

measure plexiglass cutting

Before cutting, make sure the plexiglass’ protective film is still in place; without it, you could scratch or damage its surface.

(Looking for the ideal power tool for small spaces? Then, here are the best table saws for small shop that you can consider)

Step 5: Start Cutting

Once you’re ready, put on your safety glasses for protection and turn on your table saw.

To safely cut plexiglass, place the protective film side face down and carefully guide it into the saw, ensuring that one end is snug against the fence. Whether you’re a beginner or an experienced woodworker, using a push block is highly recommended for enhanced safety during the cutting process.

This tool allows you to put more distance between your fingers and the blade, so it’s much easier to guide the plexiglass forward. It also reduces vibrations, which cause jagged edges.

measure plexiglass cutting

While feeding the plexiglass through the machine, remember to move slowly and steadily. If you go too fast in cutting plexiglass with your table saw, the plexiglass could chip or melt, ruining the end product.

Similarly, if you don’t apply even pressure, the saw could vibrate and make rough, uneven cuts. If you’re working with thin plexiglass sheets, consider stacking them up, clamping them in place, and feeding them through the saw together to save time.

To prevent the table saw from overheating, pause every few minutes or so to cool down the blade. It may seem unnecessary, but this lessens the likelihood of the plexiglass cracking in the middle of the process.

Step 6: Sand and Polish the Edges

After cutting, all that’s left to do is to polish up your work.

Smooth the edges with a waterproof sandpaper and repeat this multiple times until you achieve your desired result. Afterward, use an electric drill with a buffing pad for an even more refined look.

(To get the right power tool for this project, you can always check this list of top table saws below 500 here)

Conclusion

Now that you know how to cut plexiglass using a table saw, you won’t have to call up a professional to do it for you next time. Just make sure you read through the directions properly and follow all the safety precautions for a successful outcome.

For table saw tips and tricks, these pages are worth reading: 

Ways to make your table saw larger

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Robert Johnson is a passionate furniture maker & carpenter, sought after for his knowledge on the craft.
You’ve probably seen his down-to-earth wisdom in USA Today, Bobvila, Family Handyman, and The Spruce, where he has shared commentary and guidance on various woodworking topics.

Robert is the brain behind Sawinery, where he aims to share tips, tricks, and a passion for all things carpentry.

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