How to Cut Plexiglass With a Circular Saw

If you buy something through our posts, we may get a small commission. Read more here.

Plexiglass has been one of the best alternatives to regular glass. It has a ton of uses and applications, perfect for your daily use. However, you have one chance to cut the glass correctly to avoid ruining your whole project. 

Today, I’ll teach you how to cut plexiglass using a circular saw. Thanks to these straightforward steps, you can finish your DIY project in no time.

What You Need

Before I dive into the actual steps and procedures, I want to emphasize the importance of proper preparation. It’s a critical aspect that can save a significant amount of time and energy while also helping me understand where each component should go and what I’ll need. To make this process more straightforward and avoid unnecessary hassle, I’ve put together a handy checklist below.

Circular Saw and Plexiglass

Of course, the circular saw and plexiglass [1] are the superstars of your project, so you’ll need to get them first. Aside from these two, other essential materials you need include:

green circular saw on wooden surface

 Before you start working with your plexiglass and circular saw, make sure they’re in perfect condition. Check out your plexiglass and look for unnecessary scratches or dents that would affect its quality. As much as possible, you want your plexiglass to be in tip-top shape.

When it comes to my circular saw, I always recommend running a quick test before I start any project. It’s crucial to confirm that it’s in good working condition to prevent any unexpected issues during my work. Plus, I make sure I’m fully familiar with the operation of the circular saw to ensure safety and efficiency.

To make better markings, using top-notch guides for circular saw is a smart choice. 

Well Lit Room With Proper Ventilations

The next thing you need to look for is a well-lit working space that provides proper ventilation. Handling tools in a poorly lit room is hazardous and increases the chances for accidents and errors.

upgrade woodworking workshop

The same goes for well-ventilated working spaces. You should always look for an area where the nasty fumes can exit. If not, you’ll risk feeling tired and ill later on. Plus, having enough ventilation also helps with regulating room temperature.

Clear Working Area

In my experience, handling equipment can pose challenges and potential risks, especially in a cluttered workspace. To maintain a smooth and safe project workflow, I always make it a point to clear my worktable of any unnecessary items that could obstruct my workspace. This practice not only reduces the risk of workplace injuries but also creates an environment that fosters efficiency in completing the project.

Cleaning your working area isn’t that hard. All you need to do is to return all your tools back to their respective containers and clear your table of trash or dust. The results give you a cleaner setup.

Protective Gear

Finally, always wear protective gear when you’re working with sharp equipment. You want to prevent causing any bodily injury to yourself. Here is some protective gear you need: 

Steps to Cut Plexiglass

Now that you’ve got all your materials down, it’s finally time to get started with the cutting. We’re sure you’re excited about this part, so let’s get straight to it.

 Step 1: Get your plexiglass and measuring tape. Start marking the plexiglass based on your measurements. Use a ruler to keep the markings straight and accurate. Give at least an inch worth of extra space for you to polish the material later on. 

 Step 2: Using an excellent woodworking clamp, you can now clamp your plexiglass on the working table so that it stays in place while you’re cutting. 

cutting plexiglass with circular saw

 Step 3: Using your circular saw or even a worm drive type circular saw, start cutting along the edges of your markings. Do the same for all plexiglass that needs to be cut. Make sure to wear your protective equipment at all times. 

 Step 4: Once complete, smooth the edges down with your sandpaper. Rub the edges of your cut plexiglass until it becomes even and sleek. 

 Optional Step 5: If you want the edges to have a nice shine like the rest of the body, you can buff or polish it.

Conclusion

So, those are the simple steps for cutting plexiglass using a circular saw. Before we finish up, I’d like to stress one essential piece of advice: never overlook safety precautions.

My aim is to help you successfully complete your DIY project while keeping you safe. Accidents can happen when we become complacent with our bodies and hands. Always bear in mind the importance of wearing the appropriate personal protective equipment (PPE), especially when working with a powerful tool like a circular saw, which can effortlessly cut through materials. Your safety should always come first.

You can also check other related articles including how to cut laminating floor with the use of a circular saw here. Read next! 

robert headshot

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.

Related Articles
Join our community on facebook and get 3 woodworking plans for free!