Working with Plexiglass

Sometimes a woodworking project calls for the use of Plexiglass, which requires a bit of additional care and attention, but fortunately this material can be handled with tools that you might already have in your woodworking shop (plus a couple of minor additions). To safely machine Plexiglas in your shop, follow these steps:

Cut to size on your table saw. Before making any cuts, it’s important to install the right blade for the task at hand. Plexiglass has different cutting characteristics compared to wood, and you will want to use a blade that is made with the correct tooth geometry such as the blade that is shown in this video. As you make your cuts, it is also critical to have a blade guard in place and take all the precautions that you normally would, including wearing eye protection. If your project doesn’t feature exposed edges on the Plexiglass (such as being set in a wooden door frame), then you can skip the next steps and simply use it as it comes off of the table saw. The edges should be fairly clean, non-chipped, with some minor marks from the saw blade.

Finish the edges. If you want to clean up the edges of your Plexiglass following the table saw cut, a good way to accomplish this is by jointing the edges at the router table. A good quality solid carbide spiral bit is recommended to give you the cleanest edge possible. Another way to improve the edge is to use a deburring tool to ease the corners. And as a final step, treating the edges with heat can give you a professional looking result.